WO2005057635A1 - 投影露光装置及びステージ装置、並びに露光方法 - Google Patents
投影露光装置及びステージ装置、並びに露光方法 Download PDFInfo
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- WO2005057635A1 WO2005057635A1 PCT/JP2004/018604 JP2004018604W WO2005057635A1 WO 2005057635 A1 WO2005057635 A1 WO 2005057635A1 JP 2004018604 W JP2004018604 W JP 2004018604W WO 2005057635 A1 WO2005057635 A1 WO 2005057635A1
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- substrate
- wafer
- liquid
- exposure apparatus
- projection
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Classifications
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70216—Mask projection systems
- G03F7/70341—Details of immersion lithography aspects, e.g. exposure media or control of immersion liquid supply
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/20—Exposure; Apparatus therefor
- G03F7/2041—Exposure; Apparatus therefor in the presence of a fluid, e.g. immersion; using fluid cooling means
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70691—Handling of masks or workpieces
- G03F7/70716—Stages
Definitions
- the present invention relates to a projection exposure apparatus, a stage apparatus, and an exposure method, and more particularly, to a projection exposure apparatus used in lithography for manufacturing electronic devices such as semiconductor elements and liquid crystal display elements, and the projection exposure
- the present invention relates to a stage apparatus suitable as a sample stage of a precision machine such as an apparatus, and an exposure method performed by the exposure apparatus.
- a projection exposure apparatus for transferring each shot area on a photosensitive substrate (hereinafter referred to as “substrate” or “wafer”) such as a wafer or a glass plate coated with a resist (photosensitive agent).
- substrate a photosensitive substrate
- wafer a photosensitive substrate
- resist photosensitive agent
- the resolution of the projection optical system provided in the projection exposure apparatus becomes higher as the wavelength (exposure wavelength) of exposure light to be used is shorter and as the numerical aperture (NA) of the projection optical system is larger. Therefore, with the miniaturization of integrated circuits, the exposure wavelength used in the projection exposure apparatus is becoming shorter year by year, and the numerical aperture of the projection optical system is also increasing.
- the mainstream exposure wavelength is 248 nm power S of KrF excimer laser, and 193 ⁇ m of short wavelength ArF excimer laser are also put to practical use.
- ⁇ k ⁇ ⁇ / ⁇ 2 (2)
- NA the numerical aperture of the projection optical system
- k and k are process coefficients.
- the depth of focus is narrowed due to the shortening of the wavelength of exposure light and the enlargement of the projection optical system. Then, in order to cope with the further high integration of integrated circuits, it is considered that the exposure wavelength will be further shortened in the future. There is a risk that the margin will run short.
- the liquid immersion method has been proposed as a method of substantially shortening the exposure wavelength and making the focal depth larger (wider) than in the air.
- this immersion method the space between the lower surface of the projection optical system and the wafer surface is filled with a liquid such as water or an organic solvent, and the wavelength of exposure light in the liquid is 1 / n times in air (n is A projection optical system that improves the resolution by utilizing the fact that the refractive index of the liquid is usually about 1.2 to 1.6, and that the same resolution as that of the resolution is obtained by the immersion method (such as Of the projection optical system can be increased by n times in comparison with the case where it is possible to produce a projection optical system, that is, the focal depth is expanded by n times compared to that in air.
- the tip of the optical element on the substrate side of the projection optical system and the surface of the substrate Since the liquid is supplied between the surfaces, that is, the liquid is supplied to a part of the substrate surface, the pressure by this liquid (the surface tension and the weight of water are the main factors) causes the substrate
- the substrate table on which the lens is placed may be deformed or the distance between the projection optical system and the substrate may be changed.
- the substrate table sometimes vibrates as the liquid is supplied.
- the deformation of the substrate or the substrate table described above causes an error in the measurement of the position of the substrate on the substrate table measured by the laser interferometer.
- the laser interferometer indirectly measures the position of the reflection surface on the premise that the positional relationship between the reference reflection surface (for example, the movable mirror reflection surface) and the substrate is constant. It is because it measures the position of the substrate.
- the fluctuation of the distance between the projection optical system and the substrate can be determined by changing the distance between the projection optical system and the projection optical system. It causes a positional error of the substrate in the direction of the optical axis of the projection optical system, which is adjusted based on the output of the waste sensor.
- the substrate position error based on the optical axis direction of the projection optical system occurs during the exposure, the substrate based on the output of the focus sensor. This is because even if feedback control of the position of the substrate in the optical axis direction is performed through the stage, the probability that control delay occurs in focus control of the substrate is high.
- Patent Document 1 International Publication WO 99/49504 Pamphlet
- a liquid is supplied between the projection optical system and the substrate, and the projection optical system and the liquid are Through the group
- a projection exposure apparatus comprising: a correction device that corrects a positional deviation that occurs in at least one of the two.
- displacement caused in at least one of the substrate and the substrate table due to the supply of the liquid means the in-plane direction of the movement surface of the substrate table caused due to the supply of the liquid and It includes misregistration in any direction in the direction orthogonal to the plane of movement.
- the correction device corrects the positional deviation that occurs in at least one of the substrate and the substrate table due to the supply of the liquid.
- the immersion method is applied to the substrate under the same conditions as in the dry type projection exposure apparatus, that is, in the situation where there is at least one positional deviation between the substrate and the substrate table due to the supply of liquid.
- the high-precision exposure used is realized.
- the correction device when further including a position measurement system for measuring the position information of the substrate table, the correction device is caused by the supply of the liquid according to the position of the substrate table. It is possible to correct the positional deviation that occurs in at least one of the substrate and the substrate table.
- the correction device generates an error in at least one of the position information of the substrate and the substrate table, which is measured directly or indirectly by the position measurement system, which is caused by the supply of the liquid. It can be corrected.
- the correction device can correct a positional deviation caused by a change in shape of the substrate table.
- the substrate table has a reference member for positioning, and the correction device corrects the positional deviation between the reference member and the substrate. S can.
- the correction device can correct the distance between the substrate and the projection optical system in the direction of the optical axis of the projection optical system.
- the correction device can correct the positional deviation in accordance with the physical quantity of the liquid.
- the liquid The physical quantity can be a force S that includes at least one of the pressure of the liquid and the surface tension of the liquid.
- the correction device can correct the positional deviation caused by the vibration of the substrate table.
- the projection exposure apparatus of the present invention further comprises a mask stage on which the mask on which the pattern is formed is placed and which can be moved while holding the mask, and the correction device includes the substrate table and the mask.
- the displacement applied to at least one of the stages can be changed to correct the displacement.
- the correction device can include a control device that changes the thrust by feedforward control.
- the correction device can correct the positional deviation based on the result of measuring the position of the transferred image of the pattern transferred onto the substrate.
- the correction device may correct the positional deviation based on a simulation result.
- a stage apparatus having a substrate table which movably holds a substrate to which liquid is supplied on the surface, the position at which position information of the substrate table is measured.
- a stage device comprising: a measuring device; and a correction device that corrects a positional deviation that occurs in at least one of the substrate and the substrate table due to the supply of the liquid.
- the correction device corrects the positional deviation that occurs in at least one of the substrate and the substrate table due to the supply of the liquid. For this reason, it is possible to move the substrate and the substrate table based on the measurement result of the position measurement apparatus which is not affected by the liquid supplied to the surface of the substrate.
- the correction device can correct positional deviation caused by a change in shape of the substrate table.
- the substrate table has a reference member for positioning, and the correction device corrects the positional deviation between the reference member and the substrate. it can.
- a liquid is supplied between a projection optical system and a substrate held by a substrate table, and a pattern is formed on the substrate via the projection optical system and the liquid.
- a transfer step of transferring to the substrate is performed by a substrate.
- FIG. 1 is a view showing a schematic configuration of a projection exposure apparatus according to an embodiment of the present invention.
- FIG. 2 is a perspective view showing the wafer table of FIG. 1;
- FIG. 3 A sectional view showing a liquid supply / discharge unit together with a lower end portion of a lens barrel and a piping system.
- FIG. 4 is a cross-sectional view taken along the line B-B in FIG.
- FIG. 5 is a view showing a state in which liquid is supplied to the liquid supply / discharge unit.
- FIG. 6 is a view for explaining a focus position detection system.
- FIG. 7 is a block diagram showing the configuration of a control system of the projection exposure apparatus according to the embodiment with a part omitted.
- FIG. 8 is a block diagram showing a wafer stage control system built inside the stage control apparatus.
- FIG. 1 shows a schematic configuration of a projection exposure apparatus 100 according to an embodiment of the present invention.
- the projection exposure apparatus 100 is a step-and-scan projection exposure apparatus (check, scanning).
- the projection exposure apparatus 100 includes an illumination system 10, a reticle stage RST for holding a reticle R as a mask, a projection unit PU, and a stage having a wafer table 30 as a substrate table on which a wafer W as a substrate is placed.
- An apparatus 50 and control systems therefor are provided.
- the illumination system 10 includes a light source, an optical integrator, and the like as disclosed in, for example, Japanese Patent Application Laid-Open No. 2001-313250 and corresponding US Patent Application Publication No. 2003/0025890. It is configured to include an illuminance equalizing optical system, a beam splitter, a relay lens, a variable ND filter, a reticle blind, and the like (re, not shown). This In the illumination system 10, a slit-like illumination area portion specified by the reticle blind on the reticle R on which a circuit pattern or the like is drawn is illuminated with illumination light (exposure light) IL with substantially uniform illuminance.
- illumination light exposure light
- ArF excimer laser light (wavelength 193 nm) is used as illumination light IL as an example.
- illumination light IL it is also possible to use far-ultraviolet light such as KrF excimer laser light (wavelength 248 nm) or a bright line (g-line, i-line or the like) in the ultraviolet range from an ultrahigh pressure mercury lamp.
- an optical integrator a fly's eye lens, a rod integrator (internal reflection type integrator), a diffractive optical element, or the like can be used.
- the illumination system 10 for example, the configuration disclosed in Japanese Patent Laid-Open No. 6-349701 and US Pat. No. 5,534, 970 corresponding thereto may be adopted.
- the disclosures in the present specification will be made with the disclosure of each of the above publications and the corresponding US patent application disclosure specification or US patent. Be part.
- the reticle R force is fixed on the reticle stage RST by, for example, vacuum suction.
- Reticle stage RST is aligned with the optical axis of illumination system 10 (refer to projection optical system PL described later, for example, by reticle stage drive unit 11 including a linear motor etc. (not shown in FIG. 1, see FIG. 7).
- reticle stage drive unit 11 including a linear motor etc. (not shown in FIG. 1, see FIG. 7).
- reticle interferometer reticle laser interferometer
- a movable mirror having a reflective surface orthogonal to the Y-axis direction and a movable mirror having a reflective surface orthogonal to the X-axis direction are provided on the reticle stage RST.
- the end face of reticle stage RST may be mirror-finished to form a reflection surface (corresponding to the reflection surface of movable mirror 15).
- at least one corner cube type mirror for example, a retroreflector is used instead of the reflecting surface extended in the X axis direction used for position detection of reticle stage RST in the traveling direction (Y axis direction in this embodiment). Even good.
- the reticle ⁇ interferometer is a two-axis interferometer having two axes of measurement axes, and based on the measurement values of this reticle ⁇ interferometer, reticle stage RST In addition to the weir position, we can measure the rotation in the ⁇ direction, which is the rotational direction around the weir axis.
- the measurement values of reticle interferometer 16 are sent to stage control device 19, and based on the measurement values of reticle interferometer 16, position of reticle stage RST in the X, ⁇ , ⁇ ⁇ directions in stage control device 19. Is calculated, and the calculated position information is supplied to main controller 20.
- the stage control device 19 drives and controls the reticle stage R ST via the reticle stage drive unit 11 based on the position of the reticle stage RST in accordance with an instruction from the main control device 20.
- a pair of reticle alignment detection systems 12 (however, in FIG. 1, the reticle alignment detection system 12 on the back side of the drawing is not shown) is disposed above the reticle R at a predetermined distance in the X-axis direction. ing.
- Each reticle alignment detection system 12 includes an epi-illumination system for illuminating a mark to be detected with illumination light of the same wavelength as that of the illumination light IL, which is not shown here, and a mark of the detection target And a detection system for capturing an image of the object.
- the detection system includes an imaging optical system and an imaging device, and the imaging result by this detection system (that is, the detection result of the mark by the reticle alignment detection system 12) is supplied to the main control device 20.
- a mirror (not shown) for guiding the emitted illumination light onto the reticle R and guiding the detection light generated from the reticle R to the detection system of the reticle alignment detection system 12 by means of the illumination.
- Mirror is removably placed on the optical path of the illumination light IL, and when the exposure sequence is started, before irradiation of the illumination light IL for transferring the pattern on the reticle R onto the wafer W Also, based on a command from the main control unit 20, the epi-reflection mirror is retracted out of the optical path of the illumination light IL by a drive unit (not shown).
- the projection unit PU is disposed below the reticle stage RST in FIG.
- the projection unit PU includes a lens barrel 40, a plurality of optical elements held in a predetermined positional relationship within the lens barrel 40, and more specifically, a plurality of lenses having a common optical axis.
- a projection optical system PL which is a force.
- An example of projection optical system PL For example, a dioptric system is used which is both-side telecentric and has a predetermined projection magnification (for example, 1 ⁇ 4 or 1 ⁇ 5). Therefore, when the illumination area of reticle R is illuminated by illumination light IL from illumination system 10, the illumination area that has passed reticle R causes the illumination area to pass through projection unit PU (projection optical system PL).
- a reduced image (a reduced image of a part of the circuit pattern) of the circuit pattern of the reticle R is formed on the wafer W coated with a resist (photosensitive agent) on the surface.
- exposure is performed by applying the liquid immersion method as described later, and therefore, as an optical element on the most image plane side (wafer W side) that constitutes projection optical system PL.
- a liquid supply / discharge unit 32 is attached so as to surround the tip of the lens barrel 40 holding the lens 42. The configuration and the like of the liquid supply and discharge unit 32 and the piping system connected thereto will be described in detail later.
- an off-axis' alignment system (hereinafter abbreviated as' alignment system ') AS is disposed.
- this alignment system AS for example, a broad detection light flux which does not expose the resist on the wafer is irradiated to the target mark, and the image of the target mark formed on the light receiving surface by the reflected light from the target mark
- An image processing FIA Field Processing Method for imaging an image of an illustrated index (index pattern on an index plate provided in an alignment system AS) using an imaging device (CCD or the like) and outputting an imaging signal thereof Image Alignment) sensors are used.
- the alignment system AS is not limited to the FIA system, but emits coherent detection light to the target mark, detects scattered light or diffracted light generated from the target mark, or two diffractions generated from the target mark
- an alignment sensor that detects light (for example, diffracted light of the same order or diffracted light diffracted in the same direction) by interference alone or in combination as appropriate.
- the imaging result of this alignment system AS is output to main controller 20.
- the stage device 50 includes a wafer stage WST, a wafer holder 70 provided on the wafer stage WST, and a wafer stage drive unit 24 for driving the wafer stage WST.
- the wafer stage WST is disposed on the base (not shown) below the projection optical system PL in FIG. 1 and is driven in the XY direction by a linear motor or the like (not shown) that constitutes the wafer stage drive unit 31.
- the ⁇ ⁇ ⁇ ⁇ ⁇ tilt drive mechanism (not shown), which is placed and constitutes the wafer stage drive unit 24, rotates in the direction of the ⁇ axis and in the direction of inclination with respect to the ⁇ surface (rotation direction about the X axis ( ⁇ X direction) and rotation about the ⁇ axis).
- the wafer table 30 finely driven in the direction ( ⁇ y direction).
- the wafer holder 70 is mounted on the wafer table 30, and the wafer W is fixed by vacuum suction or the like by the wafer holder 70.
- This wafer holder 70 is, as shown in the perspective view of FIG. 2, one of the diagonals of square wafer table 30 in the peripheral portion of the area (the central circular area) on which wafer W is placed.
- the surface of the auxiliary plate 22a 22d is approximately the same height as the surface of the wafer W (the difference between the heights of the two is at most about 1 mm).
- the dimension of the gap D is set to be 3 mm or less. It has been.
- the force at which a notch (V-shaped notch) is present in a part of the wafer W is not illustrated, because the dimension of the notch is smaller than the gap D and is about 1 mm.
- a circular opening is formed in a part of the auxiliary plate 22a, and a reference mark plate FM is fitted in the opening so as to have no gap.
- the fiducial mark plate FM is coplanar with the surface force auxiliary plate 22a.
- At least a pair of reticle alignment reference marks, a reference mark (all not shown) for baseline measurement of alignment system AS, etc. are formed on the surface of the reference mark plate FM. That is, the reference mark plate F M also serves as a reference member for positioning the wafer table 30.
- the XY stage 31 not only moves in the running direction (Y-axis direction), but also positions a plurality of shot areas on the wafer W in an exposure area conjugate with the illumination area.
- the operation of scanning (scanning) exposing each shot area on the wafer W and the next shot Movement to the acceleration start position (scanning start position) for exposure (movement between shot areas Step) and repeat 'and' scan operation In order to be able to move in the non-scanning direction (X-axis direction) orthogonal to the scanning direction, the operation of scanning (scanning) exposing each shot area on the wafer W and the next shot Movement to the acceleration start position (scanning start position) for exposure (movement between shot areas Step) and repeat 'and' scan operation.
- the position of wafer table 30 in the XY plane is determined by means of moving mirror 17 provided on the upper surface of wafer table 30.
- moving mirror 17 provided on the upper surface of wafer table 30.
- wafer interferometer this will be called “wafer interferometer” 18 is constantly detected, for example, with a resolution of about 0.5-l nm.
- the wafer W is suctioned and fixed via the wafer holder 70 on the wafer table 30. Therefore, unless the wafer table 30 is deformed, the positional relationship between the movable mirror 17 and the wafer W is kept constant, so it is not possible to measure the position of the wafer table 30 via the movable mirror 17.
- the position of the wafer W will be measured indirectly via the moving mirror 17. That is, the reflection surface of the movable mirror 17 also serves as a reference for measuring the position of the wafer W, and the movable mirror 17 is a reference member for measuring the position of the wafer W.
- Y moving mirror 17 Y having a reflecting surface orthogonal to the traveling direction (Y-axis direction) on wafer table 30 and the non-scanning direction
- An X moving mirror 17X is provided which has a reflecting surface orthogonal to the (X axis direction), and correspondingly, the wafer interferometer also irradiates an interferometer beam perpendicularly to the X moving mirror 17X;
- a force is provided which irradiates the interferometer beam perpendicularly to the mirror 17Y and the Y interferometer is provided.
- FIG. 1 these are representatively shown as the movable mirror 17 and the wafer interferometer 18.
- the X interferometer and the Y interferometer of the wafer interferometer 18 are both multi-axis interferometers having multiple measurement axes, and with these interferometers, the wafer stage WST (more precisely, the wafer table 30 Of course), pitching (rotation about the X-axis, ⁇ X rotation), rolling (rotation about the Y-axis, rotation ⁇ y) It is also possible to measure)).
- the wafer stage WST more precisely, the wafer table 30 Of course
- pitching rotation about the X-axis, ⁇ X rotation
- rolling rotation about the Y-axis, rotation ⁇ y
- the multi-axis interferometer irradiates the laser beam to the reflecting surface installed on the frame (not shown) on which the projection optical system PL is mounted via the reflecting surface installed on the wafer tape 30 inclined by 45 °. Good, even if it detects relative position information about the optical axis direction (Z-axis direction) of the projection optical system PL.
- the measurement values of the wafer interferometer 18 are sent to a stage control unit 19.
- the stage control unit 19 uses the X, Y positions of the wafer table 30 based on the measurement values of the wafer interferometer 18. And calculate the ⁇ z rotation. In addition, if the ⁇ X rotation and ⁇ ⁇ y rotation of the wafer table 30 can be calculated based on the output of the wafer interferometer 18, the positional error in the XY plane of the wafer table 30 caused by the rotation is corrected. Calculate the X and Y positions of wafer table 30. Then, information on the X, Y positions and ⁇ z rotation of the wafer table 30 calculated by the stage control device 19 is supplied to the main control device 20.
- the stage control device 19 controls the wafer table via the wafer stage drive unit 24 based on the positional information of the wafer table 30 in accordance with an instruction from the main control device 20.
- a wafer stage control system (which will be described in detail later) and a reticle stage control system (not shown) are constructed in the stage control apparatus 19 of the present embodiment.
- FIG. 3 the liquid supply / discharge unit 32 is shown in a cross-sectional view along with the lower end portion of the barrel 40 and the piping system. Further, FIG. 4 shows a cross-sectional view taken along the line B-B in FIG.
- a small diameter portion 40a having a diameter smaller than that of the other portion is formed at the end (lower end) of the image plane side of the barrel 40 of the projection unit PU.
- the smaller diameter portion 40a has a tapered portion 40b whose diameter decreases as it goes downward.
- the lens 42 on the most image plane side of the projection optical system PL is held inside the small diameter portion 40a.
- the lower surface of the lens 42 is parallel to the XY plane orthogonal to the optical axis AX.
- the liquid supply / discharge unit 32 has a cylindrical shape as viewed from the front (and the side), and at its central portion, as shown in FIG.
- An opening 32a which can be inserted from the upper side (+ Z direction) to the lower side (one Z direction) is formed in the vertical direction.
- the opening 32a is a generally circular opening as a whole provided with arc-shaped portions 33a and 33b having a larger diameter than parts of one side and the other side in the X-axis direction as compared to other parts (FIG. 4). reference).
- the inner wall surfaces of the arc-shaped portions 33a and 33b of the opening 32a have a substantially constant diameter from the upper end to the vicinity of the lower end, as shown in FIG.
- Air gaps are formed respectively.
- One end portions of the plurality of supply tubes 52 are inserted in the vertical direction at substantially equal intervals into these gaps, and the open end on one end side of each supply tube 52 faces the liquid supply port 33a or the liquid supply port 33b. I see.
- each of the supply pipes 52 is connected to the other end of the supply pipe 66 whose one end is connected to the liquid supply device 74 via a valve 62 b.
- the liquid supply device 74 includes a liquid tank, a pressure pump, a temperature control device, and the like, and is controlled by the main control device 20. In this case, when the liquid supply device 74 is operated when the corresponding valve 62b is open, for example, the temperature is approximately the same as the temperature in the chamber (not shown) in which the (main body) of the exposure device 100 is housed.
- a predetermined liquid for immersion whose temperature is controlled by the temperature control device, passes between the liquid supply / discharge unit 32 and the lens 42 and the wafer W surface via the respective supply pipes 52 and the liquid supply ports 33a and 33b.
- Supply in the gap of FIG. 5 shows how the liquid is supplied in this way.
- valve 62b provided in each supply pipe 52 is collectively described as a group 62b (see FIG. 7).
- the tank for supplying the liquid, the pressure pump, the temperature control device, the valve, etc. need to have all of them in the exposure apparatus 100. At least a part of the plant should be provided with the exposure apparatus 100. It can also be replaced by equipment such as
- ultra pure water through which ArF excimer laser light (light having a wavelength of 193.3 nm) is transmitted (hereinafter simply referred to as "water” unless particularly required) Shall be used.
- Ultrapure water can be easily obtained in large quantities in semiconductor manufacturing plants etc., and has the advantage that it does not adversely affect the photoresist on the wafer, the optical lens, etc. Further, since ultrapure water has no adverse effect on the environment and the content of impurities is extremely low, the effect of cleaning the surface of the wafer and the surface of the lens 42 can also be expected.
- Each is formed into a cross-sectional shape, and serves as a liquid recovery port.
- these liquid recovery ports are referred to as “liquid recovery port 32b, liquid using the same reference numerals as those of the concave portions 32b and 32b, as appropriate.
- the liquid recovery device 72 includes a liquid tank, a suction pump, and the like, and is controlled by the main controller 20. In this case, when the corresponding valve 62a is in the open state, the water in the gap between the liquid supply / discharge unit 32 and the lens 42 described above and the wafer W surface is the liquid recovery ports 32b and 32b and the respective recovery.
- valves 62a provided in the respective recovery pipes 58 are collectively referred to as a valve group 62a (see FIG. 7).
- the tank, the suction pump, the valve, etc. for recovering the liquid need to have all of them in the exposure apparatus 100 at least partially replaced by facilities such as a factory where the exposure apparatus 100 is installed. You can also
- a control valve for example, a flow control valve or the like capable of adjusting the opening degree is used. These valves are controlled by the main controller 20 (see FIG. 7).
- the liquid supply / discharge unit 32 is fixed to the bottom of the lens barrel 40 by a screw (not shown). And, in a state where it is attached to the lens barrel 40, the lower end surface of the liquid supply / discharge unit 32 becomes the same surface as the lower surface of the lens 42 (the lowermost end surface of the lens barrel 40), as shown in FIG. ing.
- the liquid supply / discharge unit 32 has a lens 4 at its lower end face. It may be set higher than the lower surface of 2 or may be set lower.
- the exposure apparatus 100 of the present embodiment is further provided with a focus position detection system for so-called auto focus and trace of the wafer W.
- a focus position detection system for so-called auto focus and trace of the wafer W.
- a pair of prisms 44 A, 44 B made of the same material as the lens 42 and in close contact with the lens is provided between the lens 42 and the tapered portion 40 b of the lens barrel 40.
- a pair of horizontally extending through holes 40d and 40e are formed that communicate the inside and the outside of the lens barrel 40.
- Right-angle prisms 46A and 46B are disposed at the inner end (the above-mentioned air gap side) of the through holes 40d and 40e, respectively, and fixed to the lens barrel 40.
- An illumination system 90 a is disposed outside the lens barrel 40 so as to face one of the through holes 40 d.
- a light receiving system 90b which constitutes a focal position detecting system together with the irradiation system 90a is disposed opposite to the other through hole 40e.
- the illumination system 90a has a light source whose on / off is controlled by the main control unit 20 of FIG. 1, and the luminous flux for forming an image of a large number of pinholes or slits toward the image plane of the projection optical system PL. Eject in the horizontal direction. The emitted light flux is reflected vertically downward by the right angle prism 46A, and is irradiated to the surface of the wafer W from the oblique direction with respect to the optical axis AX by the above-mentioned prism 44A.
- the reflected luminous fluxes of those luminous fluxes reflected on the surface of the wafer W are reflected vertically upward by the above-mentioned prism 44B and further reflected horizontally by the right-angle prism 46B and received by the light receiving system 90b .
- the illumination system 90a, the light reception system 90b, the prisms 44A and 44B, and the right angle prisms 46A and 46B are disclosed in, for example, Japanese Patent Application Laid-Open No.
- a focus position detection system is configured, which is composed of an oblique incidence multipoint focus position detection system similar to that disclosed in the 448, 332 and the like.
- this focus position detection system will be described as a focus position detection system (90a, 90b).
- the national laws and regulations of designated countries (or selected countries) designated in this international application permit, the disclosures in the above-mentioned publications and corresponding US patents are incorporated herein by reference.
- Defocus signal (defocusing signal) which is an output of the light receiving system 90b of the focus position detecting system (90a, 90b)
- the waste signal is supplied to the stage controller 19 (see FIG. 7).
- the stage control device 19 calculates the Z position and the ⁇ , yy rotation of the surface of the wafer W based on the defocus signal (defocus signal) from the light receiving system 90b, for example, the S curve signal at the time of scanning exposure. Then, the calculation result is sent to main controller 20.
- the stage controller 19 drives the wafer stage so that the calculated Z position on the surface of the wafer W and the ⁇ X, yy rotation from the target value become zero, that is, the focus shift becomes zero.
- the irradiation area of the illumination light IL (described above Auto focusing (automatic focusing) that substantially matches the imaging surface of the projection optical system PL with the surface of the wafer W in a region (exposure region) optically conjugate to the illumination region Perform auto leveling.
- the focus position detection system (90a, 90b)
- a part of the liquid supply / discharge unit 32 is made of transparent glass to the light from the light source.
- the above-described detection may be performed using this glass.
- control system of exposure apparatus 100 is partially omitted and shown in a block diagram.
- This control system is mainly configured of a main control unit 20 including a work station (or a microcomputer) and the like and a stage control unit 19 under the control.
- FIG. 8 shows a wafer stage system 56 which is a block diagram control target of the wafer stage control system 26 built in the stage control device 19.
- the wafer stage control system 26 includes a target value output unit 28, a subtractor 29, a control unit 36, a correction value generation unit 38, an adder 39, an operation unit 54 and the like. ing.
- the target value output unit 28 creates a position command profile for the wafer table 30 in accordance with an instruction from the main controller 20, and the position command per unit time in the profile, ie, the X of the wafer table 30
- Wafer stage system 56 is a system corresponding to a control target of wafer stage control system 26, and is a system for inputting a thrust command output from adder 39 and outputting positional information of wafer table 30. . That is, the wafer stage system 56 includes the wafer stage drive unit 24 to which a thrust command output from the adder 39 is given, and a wafer table 30 driven in the direction of six degrees of freedom by the wafer stage drive unit 24.
- the position measurement system for measuring the position of the wafer table 30, that is, the wafer interferometer 18 and the focus position detection system (90a, 9Ob) substantially correspond to this.
- Wafer stage drive unit 24 is configured to include a conversion unit that converts a thrust instruction (P + ( ⁇ E)) into an operation amount for each actuator when given.
- the arithmetic unit 54 calculates positional information of the wafer table 30 in the X-axis, Y-axis and z-axis directions based on the measurement value of the wafer interferometer 18 which is the output of the position measurement system, and also measures the position. Based on the output of the focus position detection system (90a, 90b) which is the output of the system, position information of the wafer table 30 in the Z-axis, ⁇ , and 0y directions is calculated. The position information force in the direction of six degrees of freedom of the wafer table 30 calculated by the calculation unit 54 is supplied to the main control unit 20. In addition, at the time of scanning exposure, which will be described later, the wafer table calculated by this operation unit 54. Position information in the X, Y plane of 0 is input to a synchronous position calculation unit (not shown), and the synchronous position calculation unit gives a target position value to the reticle stage control system (not shown). There is.
- the correction value generation unit 38 receives the flow rate Q and the contact angle ⁇ , which are setting conditions, from the main control unit 20. There is. Then, the correction value generation unit 38 calculates the X-direction error E, the Y-direction error E ′, and the Z-direction error E ′ based on the following equations (3), (4), and (5), respectively. Then, the calculation result is converted into a correction value E of the estimation by a predetermined conversion operation to E, ⁇ E, ⁇ E, and is fed forward to the adder 39.
- the parameters X and Y in the above equations (3), (4) and (5) are command values for the position of the wafer stage WST from the target value output unit 28, and the parameters V and V are the moving speeds of the wafer stage WST ( This is the command value X for the i-th position
- the meter Q is the flow rate of water supplied, and the parameter ⁇ is the contact angle of the water to the wafer (resist on the wafer or its coating layer) is there.
- parameters X and Y are included in the above equations (3), (4), and (5) only because the pressure and surface tension etc. of the wafer W This is because, if the position of wafer stage WST on the stage coordinate system is different, the shape change of the surface of wafer table 30 caused by the force is different.
- the reason why the parameters V and V are included is as follows. That is, when the wafer table 30 moves in a predetermined direction in the XY plane, a flow of water corresponding to the moving direction and the moving speed occurs. This flow is generated due to a shear force due to the relative displacement between the surface of the hydraulic wafer, which is an incompressible viscous fluid, and a Newtonian fluid that satisfies the Newton's law of viscosity, and the lower surface of the lens 42. , A laminar flow (Couette) flow. That is, the movement velocity of the wafer table 30 The velocity of water It is one of the parameters to determine the pressure.
- the parameter Q is included because the flow rate of the supplied water is one of the parameters that determine the pressure of the water.
- the parameter ⁇ (contact angle ⁇ ) is included for the following reasons.
- the contact angle ⁇ can be determined, for example, by visual measurement or image measurement.
- the above equations (3), (4) and (5) are determined in advance based on the result of measurement exposure (test exposure) actually performed using exposure apparatus 100. ing. This will be explained below.
- measurement reticle R a measurement reticle (hereinafter referred to as “measurement reticle R” for convenience) is loaded on reticle stage RST.
- wafer stage WST a measurement reticle
- measuring wafer W a measuring wafer (hereinafter referred to as “measuring wafer W” for convenience) is loaded on the wafer holder 70.
- the measurement reticle R for example, one surface of a rectangular glass substrate (a pattern surface
- a pattern area is formed, and a plurality of measurement marks are arranged in a matrix at predetermined intervals in the pattern area. Also, this measurement reticle R
- a wafer mark (alignment mark) whose positional relationship with the center of the pattern area is known is also provided. This wafer mark is made in the process of manufacturing the measuring wafer W
- the measurement wafer W high-precision projection exposure that constitutes a device manufacturing line
- the above-mentioned measurement reticle R may be exposed by an optical device (an exposure apparatus which does not adopt the liquid immersion method is desirable).
- a wafer is used in which a turn is transferred to a plurality of shot areas, and an image (for example, a resist image or an etching image) of a plurality of measurement marks is formed on each shot area.
- Alignment marks are attached to each shot area of this measurement wafer W, and ⁇ is set.
- the photoresist is applied by The measurement wafer W force equation (3)
- the amount of positional deviation (dx, dy) of force, etc. is determined in advance, and is stored in a memory (not shown).
- reticle alignment is performed in the same manner as in the normal scanning 'stepper'.
- the illumination light IL is used as a detection light for reticle alignment
- the lens 42 positioned at the image plane side end of the projection optical system PL and the reference mark plate FM Reticle alignment is performed while water is supplied in the meantime.
- stage control device 19 controls the illumination region of the illumination light by illumination system 10 through reticle stage drive unit 11 based on the measurement value of reticle interferometer 16. In order to make the center approximately coincide with the center of measurement reticle R,
- the reticle stage PL is moved based on the measurement values of the wafer interferometer 18, and the projection optical system PL of the pattern of the measurement reticle R is moved via the wafer stage drive unit 24.
- the wafer table 30 is moved to a position where the fiducial mark plate FM is located at the projection position according to (1) (hereinafter referred to as "predetermined reference position").
- main controller 20 starts the operation of liquid supply device 74, and opens each valve of valve group 62b at a predetermined opening degree.
- water supply is started from all the supply pipes 52 through the liquid supply ports 33a and 33b of the liquid supply and discharge unit 32, and after a predetermined time has elapsed, the gap between the lens 42 and the reference mark plate FM surface It will be filled with the supplied water.
- the main control unit 20 opens each valve of the valve group 62a at a predetermined opening degree, and the water flowing out from the lower side of the lens 42 is circulated through the liquid recovery ports 32b and 32b and the recovery pipes 58.
- Collection device 72 collects.
- FIG. 5 shows the state at this time.
- main controller 20 controls the valves 62b so that the flow rate of water supplied per unit time and the flow rate of recovered water are substantially the same. And adjust the opening degree of each valve of the valve group 62a. Therefore, a fixed amount of water is always held in the gap between the lens 42 and the fiducial mark plate FM. Also, in this case, since the clearance between the lens 42 and the reference mark plate FM is at most about 1 mm, water is held between the liquid supply / discharge unit 32 and the reference mark plate FM by its surface tension. There is almost no leakage to the outside of the liquid supply / discharge unit 32.
- main controller 20 When the water supply is started as described above, and after a predetermined time has elapsed, when the gap between lens 42 and reference mark plate FM surface is filled with the supplied water, main controller 20 generates the reference mark The relative positions of the pair of first reference marks on the rectangular plate FM and the pair of reticle alignment marks on the measurement reticle R corresponding to the first reference mark
- Detect using Liment detection system 12 the detection result of reticle alignment detection system 12, positional information of reticle stage RST in the XY plane at the time of detection obtained through stage controller 19, and the XY plane of wafer table 30. Store the position information of in the memory.
- wafer stage WST and reticle stage RST are respectively moved in opposite directions along the Y-axis direction by a predetermined distance, and another pair of first reference on reference mark plate FM is obtained. Of the mark and another pair of reticle alignment marks on the measurement reticle R corresponding to the first reference mark
- the position is detected using the pair of reticle alignment detection systems 12 described above. Then, in the main control unit 20, the detection result of the reticle alignment detection system 12 and the position information of the reticle stage RST in the XY plane at the time of detection obtained through the stage control unit 19 and the XY plane of the wafer table 30. Store the location information in the memory. Furthermore, in the same manner as described above, the relative positional relationship between still another pair of first fiducial marks on fiducial mark plate FM and the reticle alignment mark corresponding to the first fiducial mark is further measured. Also good.
- main controller 20 information on the relative positional relationship between the at least two pairs of first reference marks thus obtained and the corresponding reticle alignment marks, and the respective measurements
- the traveling exposure is performed by synchronously moving the reticle stage RST and the wafer stage WS in the wafer axis direction of the wafer stage coordinate system.
- the reticle stage coordinate system Scanning of reticle stage RS ⁇ is performed based on the relative positional relationship with the wafer stage coordinate system.
- main controller 20 is projected on reference mark plate FM. Close the valves of the valve group 62b and stop the water supply while under the unit PU. At this time, each valve of the valve group 62a remains open. Therefore, the recovery of water is continued by the liquid recovery unit 72. Then, when the water on the reference mark plate FM is almost completely recovered by the liquid recovery device 72, the main control unit 20 returns the light table 30 to the predetermined reference position described above, and a predetermined amount from that position, For example, it moves in the XY plane by the design value of the baseline and detects the second fiducial mark on the fiducial mark plate FM using the alignment system AS.
- main controller 20 information on the relative positional relationship between the detection center of alignment system AS and the second reference mark obtained at this time and the pair of first reference marks measured when wafer table 30 was previously positioned at the reference position.
- Information on the relative positional relationship between the reference mark and the pair of reticle alignment marks corresponding to the first reference mark, positional information in the XY plane of the wafer table 30 at the time of each measurement, and a design value of the baseline Based on the known positional relationship between the first fiducial mark and the second fiducial mark, the distance between the baseline of the alignment system AS, ie, the projection center of the reticle pattern and the detection center (index center) of the alignment system AS. Calculate (positional relationship).
- each shot area is projected as a reticle pattern. It should be able to be reliably aligned in position
- measurement results of relative positional relationship information between a pair of first reference marks and a pair of reticle alignment marks corresponding to the first reference marks which are the basis of baseline calculation.
- This error is a value corresponding to the pressure and surface tension of water, but in the present embodiment, the simulation is performed in advance, and the positional deviations ⁇ X and ⁇ ⁇ of the pair of first reference marks are obtained, and the memory I remember it.
- main controller 20 stores the corrected baseline obtained by correcting the measured baseline by the correction value, as a new baseline, in the memory.
- main controller 20 selects a plurality of specific ⁇ selected from among a plurality of shot areas already formed on wafer W.
- Positioning of the wafer table 30 is sequentially performed via the stage control device 19 and the wafer stage drive unit 24 so that the wafer marks respectively attached to the shot areas (sample areas) are sequentially positioned within the detection field of the alignment system AS. To be executed. At each position determination, main controller 20 detects a wafer mark by alignment system AS.
- main controller 20 selects each wafer mark based on the position of the wafer mark relative to the index center, which is the detection result of the wafer mark, and the position information in the XY plane of wafer table 30 at that time. Position coordinates on the wafer stage coordinate system are calculated. Then, in main controller 20, the least square method disclosed in, for example, Japanese Patent Laid-Open No. 61-44429 and corresponding US Pat. No. 4,780, 617 using the calculated position coordinates of the wafer mark. Perform statistical calculations using the
- the array coordinates of the yacht area that is, the position coordinates of the center of each shot area are calculated and stored in a memory (not shown).
- the position coordinates of the center of each shot area calculated at this time will be described later. Is used to associate the measurement result of the measuring wafer with the wafer stage coordinate system.
- stage control device 19 starts reticle stage RST scanning start position (acceleration start position) based on the measurement value of reticle interferometer 16 based on the instruction of main controller 20.
- the wafer stage WST is moved to a predetermined water supply start position, for example, a position where the fiducial mark plate FM is positioned immediately below the projection unit PU, based on the measurement value of the wafer interferometer 18.
- main controller 20 starts operation of liquid supply device 74 and opens each valve of valve group 62b at a predetermined opening degree, and opens each valve of valve group 62a at a predetermined opening degree, Furthermore, the operation of the liquid recovery device 72 is started to start the supply of water to the gap between the lens 42 and the reference mark plate FM surface and the recovery of water from the gap. At this time, main controller 20 controls each valve of valve group 62 b and each valve of valve group 62 a so that the flow rate of water supplied per unit time and the flow rate of recovered water are substantially the same. Adjust the opening degree.
- the exposure operation of the step-and-scan method is performed as follows.
- main controller 20 instructs stage control device 19 to move wafer stage WST.
- the stage control unit 19 monitors the measurement values of the wafer interferometer 18 and exposes the first shot (first shot area) of the measuring wafer W.
- the scan start position is the center position coordinate of the shot area to be transferred and formed by the running exposure, with respect to the center position coordinate of the first shot obtained by the above-described wafer alignment.
- the position is shifted by a predetermined distance (for example, w) in the X-axis direction. In this way, it is already formed on the measuring wafer w.
- main controller 20 continues the water supply and recovery in the same manner as described above.
- main controller 20 When movement of measurement wafer W to the acceleration start position described above is completed, main controller 20
- stage controller 19 controls reticle stage RST and wafer stage
- a relative scan with the WST in the Y-axis direction is started.
- the relative traveling edge is obtained by combining the wafer stage control system 26 described above and the wafer stage control system.
- the reticle stage RS based on the target value of the position calculated by the synchronous position calculation unit based on the position information in the X and Y planes of the wafer table 30 calculated by the calculation unit 54.
- the correction value generation unit 38 outputs (0, 0, 0 as a correction value).
- the illumination light IL starts to illuminate the pattern area of the measurement reticle R, and scanning exposure is started.
- stage control device 19 which controls both stages RST and WST so that the speed ratio is maintained.
- Reduction optics are transferred to the first shot on the measurement wafer W via the shadow optics PL and water.
- the main control device At the time of exposure exposure to the first shot on the measurement wafer W described above, the main control device
- the positioning unit 20 moves the projection unit P with respect to the traveling direction, ie, the moving direction of the measuring wafer W.
- valve positions of the valve groups 62a and 62b are adjusted so that the flow of water moving from the back side to the front side of U is generated below the lens 42. That is, main controller 20 With regard to the movement direction of the measurement wafer W, it is supplied from the supply pipe 52 on the rear side of the projection unit PU.
- the total flow rate of the water to be supplied is A Q more than the total flow rate of water supplied from the supply pipe 52 on the rear side of the projection unit PU, corresponding to the movement direction of the measuring wafer W
- Projection unit The total flow force of the water recovered via the recovery pipe 58 on the front side of the projection valve The valve so that the total flow rate of water recovered via the recovery pipe 58 on the rear side of the projection unit PU is ⁇ Q more Adjust the opening degree of each of the valves that make up the groups 62a and 62b.
- the illumination area on the measurement wafer W is the projection optical system PL.
- the auto focus and auto leveling based on the output of the focus position detection system (90a, 90b) described above is more precisely , And is performed by the wafer stage control system 26 described above.
- stage controller 19 moves wafer stage WST in a step along the X-axis and Y-axis through wafer stage drive unit 24, and the second shot on measurement wafer W Start acceleration for exposure of (second shot area)
- the scan start position is relative to the center position coordinates of the second shot determined by the wafer alignment.
- the center position coordinates of the shot area to be transferred and formed by this scanning exposure are shifted by W with respect to the X-axis direction.
- main controller 20 accelerates the exposure for the first shot from the water supply start position described above.
- the opening and closing operation of each valve is performed in the same manner as when the wafer table 30 is moved to the start position.
- the same running exposure as described above is performed.
- a so-called alternating scan method is adopted. Therefore, in the case of exposure of this second shot, the traveling direction (moving direction) of reticle stage RST and wafer stage WST and the reverse direction to the first shot. become.
- the processes of the main control unit 20 and the stage control unit 19 at the time of running exposure to the second shot are basically the same as described above.
- the main controller 20 Is the projection ⁇ with respect to the moving direction of the measuring wafer w opposite to that of the first shot exposure.
- valve positions of the valve groups 62a and 62b are adjusted so that the flow of water moving from the back side to the front side of the unit PU is generated below the lens 42.
- the m-th (m is a natural number) shot area on the measurement wafer W is exposed.
- the light and the stepping operation for exposing the m + 1st shot area are repeatedly performed, and the pattern of the reticle for measurement R is applied to all the exposure target shot areas on the measurement wafer W.
- test exposure for one wafer is completed, and measurement on wafer W for measurement is performed.
- a plurality of shot areas on which the pattern of the reticle R is transferred are formed.
- the scanning exposure for measurement using the measurement reticle R is scanned.
- the speed (scan speed), the flow rate of water supplied, the type of resist or coating film applied on the wafer, etc. are closely related to the parameters of the above equations (3), (4), and (5). Conduct different conditions for each of the measurement wafers while changing various conditions individually.
- each of the exposed measurement wafers is transferred to a coater window, not shown, for development, and after development, each shot formed on each measurement wafer is developed.
- the resist image of the mask area is measured by SEM (scanning electron microscope) or the like, and the amount of displacement (X-axis direction, Y-axis direction) of each measurement mark is determined for each measurement wafer based on the measurement result. Ru.
- the amount of positional deviation (eX, eY) from the design value of each measurement mark can be obtained by the following procedure.
- the position of the resist image of the corresponding mark formed in the original step (which was already formed on the measurement wafer) is calculated.
- the center coordinates of each shot area on the wafer coordinate system set on the measurement wafer, and each shot obtained as a result of the EGA performed previously The positional shift amount (eX, eY) of each measurement mark is associated with the wafer stage coordinate system ( ⁇ , ⁇ ) as a match with the center coordinate of the area.
- the positional deviation amounts (eX, e Y) of all measurement marks of all obtained measurement wafers are obtained.
- V Since data obtained by measurement exposure is data during scanning exposure, V is normally 0, but for the purpose of correction of C character distortion of a shot area, etc., V is a variable that changes according to the function of position Y (or a variable that changes according to the function of time t).
- the transfer position of the transfer image of the measurement mark formed on the measurement wafer is determined from the reference position.
- the defocusing amount (that is, the amount of positional deviation of the mark in the Z-axis direction) eZ can also be calculated by finding it.
- the pattern may be sequentially transferred to determine the best focus position of the projection optical system PL.
- the scan speed scan speed
- the flow rate of water supplied the type of resist or coating film applied on the wafer, etc.
- the simulation is performed while variously changing conditions closely related to the parameters of the equations (3), (4), and (5) mentioned above individually, and the equation (3) described above is obtained based on the result of the simulation. It is also possible to determine), (4), (5).
- Stage controller 19 is stored in the internal memory. Further, in the internal memory of the stage control device 19, a conversion equation for converting the positional deviation amount into a thrust command value is also stored. Then, these equations are used in the correction value generation unit 38.
- Reticle R is used, and at least one circuit pattern is substituted for measurement wafer W.
- a wafer w which has already been transferred and on which a photoresist is applied is used.
- reticle alignment for reticle R is performed.
- baseline measurement of alignment system AS is performed.
- wafer alignment of EGA method for wafer W is performed.
- the same water supply and recovery operation as described above is performed by the main control unit 20.
- stage control unit 19 starts reticle stage RST scanning start position (acceleration start position) based on the measurement value of reticle interferometer 16 based on the instruction of main controller 20.
- the wafer stage WST is moved to a predetermined water supply start position, for example, a position where the fiducial mark plate FM is positioned immediately below the projection unit PU, based on the measurement value of the wafer interferometer 18.
- main controller 20 starts operation of liquid supply device 74 and opens each valve of valve group 62b at a predetermined opening degree, and also opens each valve of valve group 62a at a predetermined opening degree. Further, the liquid recovery device 72 is activated to start the supply of water to the gap between the lens 42 and the reference mark plate FM surface and the recovery of water from the gap. At this time, the Lord The controller 20 adjusts the opening degree of each valve of the valve group 62b and each valve of the valve group 62a so that the flow rate of water supplied per unit time and the flow rate of recovered water are almost the same. Do.
- the exposure operation of the step-and-scan method is performed as follows.
- main controller 20 instructs stage control device 19 to move wafer stage WST based on the result of wafer alignment and the measurement result of the baseline.
- the stage control device 19 scans the measurement values of the wafer interferometer 18 and starts the scanning start position (acceleration start position) for exposure of the first shot (first shot area) of the wafer W.
- Move wafer stage WST (wafer table 30) to.
- the target value output unit determines the acceleration start position for exposure of the first shot area (first shot) as a result of the first shot obtained as a result of the above-mentioned wafer alignment.
- the position command profile for wafer table 30 is calculated based on the acceleration start position and the current position of wafer table 30 based on the position coordinates on the stage coordinate system of the target area and the new baseline described above. Create position command per unit time in the profile, ie X, ⁇ , ⁇ , ⁇ ⁇ , ⁇ y, ⁇ z of wafer table 30
- focus position detection systems (90a, 90b) are off, so the observables ⁇ x, 0 y, ⁇ ⁇ ⁇ are all zero, and the corresponding target Since the value is also zero, the positional deviations ⁇ , ⁇ ,
- the correction value generation unit 38 calculates the above-mentioned equation (3) based on the target value T of the position from the target value output unit 28, the flow rate Q input from the main control unit 20, and the contact angle ⁇ . , (4), (5) according to X
- the directional error E ′, Y-direction error E ′, and Z-direction error E ′ are calculated, respectively, and the calculation results are converted into thrust correction values E, ⁇ E, and ⁇ E by a predetermined conversion operation.
- the adder 39 adds the command value P of the thrust from the control unit 36 and the correction value I of the thrust which is the output of the correction value generation unit 38 in each direction of each degree of freedom, and adds the corrected thrust
- the command value (P + ( ⁇ E)) (P ⁇ E, P ⁇ E, P ⁇ E, P ⁇ , P ⁇ , P) is given to the wafer stage drive unit 24 constituting the wafer stage system 56.
- thrust command values P ⁇ , ⁇ , and ⁇ are zero.
- the conversion unit converts the command value (P + ( ⁇ E)) of the thrust into an operation amount for each actuator, and wafer table 30 is moved by each actuator.
- the target value output unit 28 outputs the position command per unit time in the position command profile for the wafer table 30 to the subtractor 29 and the correction value generation unit 38 every unit time. Then, the control operation as described above is repeated, and the wafer tape is moved to the scan start position (acceleration start position) for exposure of the first shot (first shot area) of the wafer W.
- target value output unit 28 creates a position instruction profile for wafer table 30 according to the target scan speed at the time of the first shot exposure, and performs position instruction By outputting the position command per unit time in the profile to subtractor 29 and correction value generation unit 38 every unit time, acceleration of wafer table 30 is started, and at the same time, the above-mentioned synchronous position calculation unit
- the reticle stage control system starts acceleration of the reticle stage RST based on the target value of the position calculated by the above.
- the illumination light IL starts to illuminate the pattern area of the reticle R, and scanning exposure is started.
- the correction value ( ⁇ E, ⁇ E) is input from the correction value generation unit 38 of the wafer stage control system 26 to the adder 39 by feedforward, and the thrust finger output from the control unit 36 Wafer table based on the thrust command value with the nominal value (P, P) corrected with that correction value.
- wafer stage WST is driven by wafer stage drive unit 24. For this reason, positional deviation of the shot area of the exposure target on the wafer W due to the water supply in the X-axis direction and Y-axis direction, that is, the movable mirrors 17X and 17Y due to the deformation of the wafer table (and the wafer) Misalignment in the XY plane of wafer W (shot area to be exposed) due to a change in the distance (more precisely, the distance between movable mirrors 17X and 17Y and the area to be exposed on wafer W to be exposed) In this state, the pattern of the reticle R is accurately superimposed and transferred onto the shot area to be exposed.
- the wafer stage control system 26 executes autofocusing and autoleveling in which the wafer table 30 is controlled based on the observed values ⁇ , ⁇ , 6y.
- the thrust correction value (-E) in the Z-axis direction is input from the correction value generation unit 38 to the adder 39 as feedforward, and the thrust command value P output from the control unit 36 is corrected by the correction value.
- Z position of wafer table 30 is determined by the thrust command value.
- wafer control unit 20 moves wafer stage WST in the X-axis and Y-axis directions by stage control device 19 via wafer stage drive unit 24, and the second shot on wafer W (second shot) Moved to the acceleration start position for the exposure of the region).
- main controller 20 In the shot-to-shot stepping operation of wafer stage WST between the exposure of the first shot and the exposure of the second shot, main controller 20 also accelerates the exposure for the first shot from the water supply start position described above. The opening and closing operation of each valve is performed in the same manner as when the wafer table 30 is moved to the start position.
- the second shot on wafer W is subjected to the same sliding exposure as that of the fast chassis described above.
- the so-called alternate scanning method is employed. Therefore, in the case of exposure of this second shot, the traveling direction (moving direction) of reticle stage RST and wafer stage WST is the first shot. It will be in the opposite direction.
- the processes of the main control unit 20 and the stage control unit 19 at the time of scanning exposure for the second shot are basically the same as described above. Also in this case, the main control unit 20 causes the water flow moving from the back side to the front side of the projection unit PU under the lens 42 with respect to the moving direction of the wafer W opposite to that in the first shot exposure. , And adjust the opening degree of each valve constituting the valve group 62a, 62b.
- the scanning exposure of the mth (m is a natural number) shot area on the measurement wafer W and the stepping operation for the exposure of the m + 1st shot area are repeatedly performed.
- the pattern of the reticle R is sequentially transferred to all exposure target shot areas on the upper side.
- correction values -E and -E are input from feed-forward to adder 39 from correction value generation unit 38 of wafer stage control system 26. Because the thrust command value (P, P) output from the control unit 36 is driven by the wafer table 30 (wafer stage WST) force wafer stage drive unit 24 based on the thrust command value corrected by the correction value. With the positional deviation of the shot area of the exposure target on the wafer W due to the supply of water corrected in the X-axis direction and the Y-axis direction, the pattern of the reticle R is accurately superimposed on the shot area of the exposure target and transferred. Be done.
- Thrust correction value 1 from the positive value generation unit 38 in the Z-axis direction is input to the adder 39 in the feed mode, and the thrust command value P output from the control unit 36 is corrected by the correction value. Since the Z position of the wafer table 30 is controlled based on the value, the autofocus control of the wafer table 30 can be performed without a control delay, and the illumination region on the wafer W becomes a connection of the projection optical system PL. The exposure is performed substantially in agreement with the image plane.
- main controller 20 instructs stage control device 19 to move wafer stage WST to the above-mentioned drainage position. .
- the main control device 20 fully closes all the valves of the valve group 62b and fully opens all the valves of the valve group 62a. By this, after a predetermined time, the water under the lens 42 is completely recovered by the liquid recovery device 72.
- the wafer stage WST force is moved to the above-described wafer exchange position, wafer exchange is performed, and the same wafer alignment and exposure as described above are performed on the wafer after exchange.
- a correction device is configured to correct an error in the position of the wafer or the reference mark plate on the wafer table which is indirectly measured by the wafer interferometer.
- the projection unit PU projection optics
- the operation of supplying water between the wafer PU and the wafer stage W on the wafer stage W and the water recovery operation are performed in parallel, that is, the lens 42 at the tip of the projection optical system PL and the wafer stage
- exposure transfer of reticle pattern onto wafer
- this water is always changing.
- the immersion method is applied to
- the wavelength of the illumination light IL on the W surface can be shortened to 1 / n times (n is the refractive index of water 1.4) of the wavelength in air, thereby improving the resolution of the projection optical system.
- n is the refractive index of water 1.4
- the supplied water is constantly replaced, if foreign matter adheres on the wafer W, the foreign matter is removed by the flow of water.
- the focal depth of the projection optical system PL is about n times larger than that in air, it is considered that defocusing is less likely to occur during the focus / leveling operation of the wafer W described above. There is an advantage.
- the numerical aperture (NA) of the projection optical system PL can be further increased, and the resolution also improves in this respect. .
- the stage control device 19 changes the force given to the wafer table 30 to correct the positional deviation of each shot area on the wafer W caused by the water supply described above.
- the present invention is not limited to this, but particularly in the case of scanning exposure, the thrust to be applied to the reticle stage RST or the thrust applied to the wafer table 30 and the reticle stage RST is changed to supply the water described above. It is also possible to correct the positional deviation of each shot area on the wafer W caused.
- the thrust command value given to the wafer stage system is corrected by the correction value from correction value generation unit 38.
- the present invention is not limited to this.
- a configuration may be adopted in which the positional deviation output from the subtractor 29 is corrected by the correction value obtained.
- the correction value generation unit calculates a dimension correction value that can be added to or subtracted from the position deviation.
- the stage control device 19 may correct the positional shift caused by the vibration of the wafer table based on data previously obtained by simulation or experiment.
- main controller 20 performs the wafer table at the time of scanning exposure.
- the projection unit P The total flow rate of water supplied from the supply pipe 52 on the rear side of U is larger by AQ than the total flow rate of water supplied from the supply pipe 52 on the rear side of the projection unit PU, corresponding to the wafer With respect to the direction of movement of W, the total flow rate of water recovered via recovery tube 58 on the front side of projection unit PU is greater than the total flow rate of water recovered via recovery tube 58 on the rear side of projection unit PU.
- the opening degree adjustment (including full closing and full opening) of each of the valves constituting the valve groups 62a and 62b is performed so as to increase by three.
- the main controller 20 supplies water only from the supply pipe 52 on the rear side of the projection unit PU with respect to the moving direction of the wafer W at the time of traveling light exposure.
- the opening adjustment (including full closing and full opening) of each of the valves constituting the valve groups 62a and 62b is performed so that the water is collected only through the collection pipe 58 on the front side of the projection unit PU.
- the valves constituting the valve groups 62a and 62b may be maintained in the fully closed state.
- ultrapure water water
- a chemically stable liquid having a high transmittance of illumination light IL and a safe liquid such as a fluorine-based inert liquid
- a fluorine-based inert liquid for example, Fluorinert (trade name of Sliemm, USA) can be used.
- This fluorine-based inert liquid is also excellent in the cooling effect.
- PFPE perfluorinated polyether
- a filter for removing impurities from the recovered liquid may be provided in the liquid recovery device, the recovery pipe, or the like. Is desirable.
- the optical element on the most image plane side of the projection optical system PL is the lens 42.
- the optical element is not limited to the lens, and the optical element of the projection optical system PL is not limited to the lens. It may be an optical plate (parallel flat plate etc.) used to adjust the characteristics, for example, aberrations (spherical aberration, coma etc.), or it may be a simple cover glass.
- Projection optical system PL The optical element closest to the image plane (the lens 42 in the above embodiment) is a liquid due to the adhesion of scattered particles or impurities in the liquid generated from the resist upon irradiation of the illumination light IL. When in contact with water, the surface may become dirty. For this reason, the optical element is attached to the lowermost part of the lens barrel 40 so as to be removable (replaceable), and may be replaced regularly.
- the optical element in contact with the liquid is the lens 42, the cost of the replacement part is high and the time required for replacement is long, and the maintenance cost (running cost) is high. Cause a rise and a decrease in throughput. Therefore, the optical element in contact with the liquid may be, for example, a plane parallel plate which is less expensive than the lens 42.
- the range in which the liquid (water) is allowed to flow is set to cover the entire projection area of the pattern image of the reticle (the irradiation area of the illumination light IL). In order to control the flow rate, flow rate, etc., it is desirable to make the range a little larger than the irradiation area as much as possible.
- the force is that auxiliary plates 22a to 22d are provided around the area on which wafer W of wafer holder 70 is mounted.
- the exposure apparatus includes an auxiliary plate or an auxiliary plate. In some cases, it is not necessary to provide a flat plate having the same function as that on the substrate table. However, in this case, it is desirable to further provide a pipe for recovering the liquid on the substrate table so that the supplied liquid does not overflow the substrate table.
- the light source is not limited to one using an ArF excimer laser, and an ultraviolet light source such as a KrF excimer laser (output wavelength: 248 nm) may be used.
- an ultraviolet light source such as a KrF excimer laser (output wavelength: 248 nm) may be used.
- not only laser light output from each of the light sources as ultraviolet light but also infrared light emitted from a DFB semiconductor laser or fiber laser or laser light of a single wavelength in the visible light, for example, erbium (Er) Or, both erbium and ytterbium (Yb) power
- harmonics for example, wavelength 193 nm
- S-doped fiber amplifier and wavelength-converted to ultraviolet light using a nonlinear optical crystal may be used.
- the projection optical system PL is not limited to a refractive system, and may be a catadioptric system (reflection-refractive system). Also, the projection magnification is not limited to 1Z4 times, 1/5 times, etc. It may be.
- the present invention can be suitably applied to a step-and-repeat type reduction projection exposure apparatus.
- the present invention can also be applied to a twin-stage type exposure apparatus provided with two wafer stages.
- the projection exposure apparatus that corrects the positional deviation generated on the substrate (or the substrate table) due to the supply of the liquid (water) has been described, but the present invention is not limited to the projection exposure apparatus.
- the present invention can be applied to any stage apparatus having a substrate table for movably holding a substrate to which a liquid is supplied. In this case, it is good if it is equipped with a position measurement device that measures the position information of the substrate tape, and a correction device that corrects the positional deviation that occurs in at least one of the substrate and substrate table due to the supply of liquid. ,. In the case of pressure, the correction device corrects the positional deviation that occurs in at least one of the substrate and the substrate table due to the supply of the liquid. Therefore, it is possible to move the substrate and the substrate table based on the measurement result of the position measurement device which is not affected by the liquid supplied to the surface of the substrate.
- An illumination optical system including a plurality of lenses and a projection unit PU are incorporated in the exposure apparatus main body, and a liquid supply / discharge unit is attached to the projection unit PU. After that, while performing optical adjustment, attach a reticle stage or wafer stage consisting of a large number of mechanical parts to the exposure apparatus main body, connect wiring and piping, and perform general adjustment (electrical adjustment, operation check, etc.)
- the exposure apparatus of the above embodiment can be manufactured.
- the present invention is not limited to this.
- a liquid crystal for transferring a liquid crystal display element pattern to Exposure device for thin film magnetic head, thin film magnetic head, The present invention can be widely applied to an exposure apparatus for manufacturing a laser, an organic EL, a DNA chip and the like.
- a glass substrate or a silicon substrate is used to manufacture a reticle or a mask used in an optical exposure apparatus, an EUV exposure apparatus, an X-ray exposure apparatus, an electron beam exposure apparatus, etc.
- the present invention can also be applied to an exposure apparatus that transfers a circuit pattern to a wafer or the like.
- a transmissive reticle is generally used, and as a reticle substrate, quartz glass, quartz glass doped with fluorine, Fluorite, magnesium fluoride, or quartz is used.
- a step of performing functional design of the device a step of manufacturing a reticle based on this design step, a step of manufacturing a wafer from a silicon material, a pattern of the reticle by the exposure apparatus of the embodiment described above
- the steps of transferring to a wafer, device assembly steps (including dicing, bonding and packaging steps), inspection steps and the like are performed.
- the projection exposure apparatus of the present invention is suitable for the manufacture of semiconductor devices. Further, the stage device of the present invention is suitable as a sample stage of an optical device to which the liquid immersion method is applied.
Abstract
Description
Claims
Priority Applications (5)
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KR1020067008445A KR101111363B1 (ko) | 2003-12-15 | 2004-12-14 | 투영노광장치 및 스테이지 장치, 그리고 노광방법 |
JP2005516225A JPWO2005057635A1 (ja) | 2003-12-15 | 2004-12-14 | 投影露光装置及びステージ装置、並びに露光方法 |
US10/582,488 US20070081133A1 (en) | 2004-12-14 | 2004-12-14 | Projection exposure apparatus and stage unit, and exposure method |
US11/603,986 US20070064212A1 (en) | 2003-12-15 | 2006-11-24 | Projection exposure apparatus and stage unit, and exposure method |
US12/896,580 US20110019170A1 (en) | 2003-12-15 | 2010-10-01 | Projection exposure apparatus and stage unit, and exposure method |
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JP2003415893 | 2003-12-15 | ||
JP2003-415893 | 2003-12-15 |
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US11/603,986 Division US20070064212A1 (en) | 2003-12-15 | 2006-11-24 | Projection exposure apparatus and stage unit, and exposure method |
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US (2) | US20070064212A1 (ja) |
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US7671963B2 (en) | 2004-05-21 | 2010-03-02 | Asml Netherlands B.V. | Lithographic apparatus and device manufacturing method |
US8749754B2 (en) | 2004-05-21 | 2014-06-10 | Asml Netherlands B.V. | Lithographic apparatus and device manufacturing method |
US8553201B2 (en) | 2004-05-21 | 2013-10-08 | Asml Netherlands B.V. | Lithographic apparatus and device manufacturing method |
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JP2012134554A (ja) * | 2004-09-17 | 2012-07-12 | Nikon Corp | 露光装置、露光方法及びデバイス製造方法 |
JP2009065223A (ja) * | 2004-10-18 | 2009-03-26 | Asml Netherlands Bv | リソグラフィ装置及びデバイス製造方法 |
JP2006191055A (ja) * | 2004-12-28 | 2006-07-20 | Asml Netherlands Bv | リソグラフィ装置及びデバイス製造方法 |
JP2011259000A (ja) * | 2005-03-18 | 2011-12-22 | Nikon Corp | 露光方法及び露光装置、デバイス製造方法、並びに露光装置の評価方法 |
US20080212056A1 (en) * | 2005-03-18 | 2008-09-04 | Nikon Corporation | Exposure Method, Exposure Apparatus, Method for Producing Device, and Method for Evaluating Exposure Apparatus |
JP2006295151A (ja) * | 2005-03-18 | 2006-10-26 | Nikon Corp | 露光方法及び露光装置、デバイス製造方法、並びに露光装置の評価方法 |
US8638422B2 (en) | 2005-03-18 | 2014-01-28 | Nikon Corporation | Exposure method, exposure apparatus, method for producing device, and method for evaluating exposure apparatus |
WO2006101024A1 (ja) * | 2005-03-18 | 2006-09-28 | Nikon Corporation | 露光方法及び露光装置、デバイス製造方法、並びに露光装置の評価方法 |
US7804580B2 (en) | 2007-05-11 | 2010-09-28 | Kabushiki Kaisha Toshiba | Immersion exposure apparatus and method of manufacturing a semiconductor device |
JP2009164306A (ja) * | 2007-12-28 | 2009-07-23 | Nikon Corp | 較正方法、移動体駆動方法及び移動体駆動装置、露光方法及び露光装置、パターン形成方法及びパターン形成装置、並びにデバイス製造方法 |
Also Published As
Publication number | Publication date |
---|---|
US20110019170A1 (en) | 2011-01-27 |
US20070064212A1 (en) | 2007-03-22 |
JP5099530B2 (ja) | 2012-12-19 |
KR20060113689A (ko) | 2006-11-02 |
JPWO2005057635A1 (ja) | 2007-07-05 |
JP2010161411A (ja) | 2010-07-22 |
KR101111363B1 (ko) | 2012-04-12 |
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