ILLUMINATION OPTICAL SYSTEM, EXPOSURE APPARATUS, AND DEVICE MANUFACTURING METHOD

Abstract

In an illumination optical system arranged to illuminate an illumination target plane by using light from a light source, the illumination optical system includes a prism unit arranged to refract the light, an optical integrator arranged to form a plurality of light sources with light emerging from the prism unit, and an optical system arranged to introduce light emerging from the optical integrator to the illumination target plane. The prism unit includes a pair of conical refractive surface having a conical concave refractive surface and a conical convex refractive surface, and a pair of pyramidal refractive surface having a pyramidal concave refractive surface and a pyramidal convex refractive surface. At least one of the concave refractive surface and the convex refractive surface of the one pair is disposed between the concave refractive surface of the other pair and the convex refractive surface of the other pair.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate exemplary embodiments of the invention and, together with the description, serve to explain the principles of the invention.

FIG. 1 is a schematic view of an example exposure apparatus to which is applied an illumination optical system according to a first exemplary embodiment of the present invention.

FIGS. 2A, 2B and 2C are explanatory views for explaining changes of an effective light source which are obtained with pyramidal refractive surfaces.

FIGS. 3A, 3B and 3C are explanatory views for explaining changes of the effective light source which are obtained with conical refractive surfaces.

FIGS. 4A, 4B and 4C are explanatory views for explaining an effective light source formed by the illumination optical system according to the first exemplary embodiment of the present invention.

FIGS. 5A, 5B and 5C are explanatory views for explaining an effective light source formed by an illumination optical system according to a second exemplary embodiment of the present invention.

FIG. 6 is a flowchart for explaining a process of manufacturing a device by employing the exposure apparatus.

FIG. 7 is a flowchart for explaining details of a substrate process in step 4 of the flowchart shown in FIG. 6.

DESCRIPTION OF THE EMBODIMENTS

Exemplary embodiments, features and aspects of the present invention will now be described in detail in accordance with the accompanying drawings.

First Exemplary Embodiment

FIG. 1 is a schematic view of an exposure apparatus to which is applied an illumination optical system according to a first exemplary embodiment of the present invention. The exposure apparatus using the illumination optical system according to the first exemplary embodiment includes the illumination optical system, an original stage (not shown) on which is placed an original (reticle or mask) 9, a projection optical system 103, and a substrate stage (not shown) on which is placed a substrate (wafer) 11.

The illumination optical system according to the first exemplary embodiment includes a rod integrator 1, a prism unit 2, a zoom lens 5, a fly-eye integrator 6 serving as an optical integrator, and an aperture stop 12.

The optical integrator 6 is constituted by a plurality of small lenses which are two-dimensionally arranged, and it forms a plurality of secondary light sources near an emergent surface thereof. The optical integrator can be constituted, for example, by a fly-eye lens, a cylindrical lens array, a microlens array, or an optical pipe (rod).

The illumination optical system according to the first exemplary embodiment further includes an optical system for illuminating the original 9, which is disposed in an illumination target plane, with light emerging from the optical integrator. Such an optical system includes a condenser lens 7 and a masking imaging lens 8.

The prism unit 2 is made up of a first subunit comprising a prism 3a having a conical concave refractive surface and a prism 4a having a pyramidal concave refractive surface, and a second subunit comprising a prism 3b having a conical convex refractive surface and a prism 4b having a pyramidal convex refractive surface.

The rod integrator 1 converts light emitted from a light source (not shown) to light having a substantially uniform light intensity distribution at an emergent surface thereof. The rod integrator 1 is disposed with intent to suppress unevenness in the light intensity distribution of an effective light source. A similar effect to that of the rod integrator 1 can also be obtained by, instead of using the rod integrator 1, arranging a microlens unit or a diffraction optical element and placing a condenser lens behind it. A light beam emerging from the rod integrator 1 enters the prism unit 2, and the prism unit 2 produces multipole illumination. Details of the multipole illumination will be described later.

After the multipole illumination has been produced by the prism unit 2, the light beam enters the zoom lens 5. The zoom lens 5 enlarges and reduces the size of the effective light source without changing the shape of the effective light source.

Further, the fly-eye integrator 6 forms a plurality of secondary light sources to illuminate the original 9 in a superimposed manner through the condenser lens 7 and the masking imaging lens 8. A pattern of the original 9 is transferred to the substrate 11 through the projection optical system 103.

Prior to describing a method of producing the multipole illumination, an effective light source distribution formed by a pair of concave and convex pyramidal refractive surfaces 21 and 22 with complementary refracting actions is described with reference to FIGS. 2A, 2B and 2C. FIG. 2A illustrates an annular beam 20 entering one of the refractive surfaces.

As illustrated in FIGS. 2B and 2C, the distance between an optical axis 20a and a pole 20b of each light beam emerging from the other refractive surface is increased as the interval between the refractive surfaces 21 and 22 increases.

On the other hand, because a radial width of the distribution is substantially constant, the annular ratio defined by (inner radius 13/outer radius 14) is increased consequently.

Also, as illustrated in FIGS. 2B and 2C, the position of each pole 20b is farther spaced from the center as the interval between the refractive surfaces 21 and 22 increases. It is therefore apparent that an opening angle 15 is reduced as the interval between the refractive surfaces 21 and 22 increases.

Thus, as the interval between the pair of concave and convex pyramidal refractive surfaces 21 and 22 with complementary refracting actions increases, the annular ratio is increased and the opening angle 15 is reduced.

Next, an effective light source distribution formed by a pair of concave and convex conical refractive surfaces 24 and 25 with complementary refracting actions is described with reference to FIGS. 3A, 3B and 3C. FIGS. 3A, 3B and 3C illustrate the effective light source distribution formed by the pair of concave and convex conical refractive surfaces 24 and 25 with complementary refracting actions.

FIG. 3A illustrates a quadruple beam 23 entering one of the refractive surfaces 24 and 25. As illustrated in FIGS. 3B and 3C, each spot of the beam 23 is enlarged into an arc-shaped spot by the conical refractive surfaces 24 and 25. Therefore, each pole 23b about optical axis 23a of the emergent beam 23 has a shape shown in FIG. 3C. As the interval between the refractive surfaces 24 and 25 increases, the opening angle 15 is increased. Also, as the interval between the refractive surfaces 24 and 25 increases, the annular ratio defined by (inner radius 13/outer radius 14) is increased as in the case of the pyramidal refractive surfaces.

Thus, as seen from FIGS. 3B and 3C, in the prism unit using the pair of concave and convex conical refractive surfaces 24 and 25 with complementary refracting actions, as the interval between the conical refractive surfaces 24 and 25 increases, the annular ratio and the opening angle 15 are both increased.

In this first exemplary embodiment, the prism unit 2 includes the prism 3a having the conical concave refractive surface, the prism 4a having the pyramidal concave refractive surface, the prism 3b having the conical convex refractive surface, and the prism 4b having the pyramidal convex refractive surface, which are arranged in the order named from the light source side. The conical concave refractive surface and the pyramidal concave refractive surface are each a refractive surface having a concave refracting action, and the conical convex refractive surface and the pyramidal convex refractive surface are each a refractive surface having a convex refracting action. Herein, the conical refractive surfaces are formed such that the pair of concave and convex refractive surfaces has complementary refracting actions. The pyramidal refractive surfaces are also formed in a similar manner. The term “complementary” means that refractive indices are substantially the same, and that the convex surface and the concave surface have substantially the same shape in match with each other.

In this first exemplary embodiment, each concave refractive surface is formed on the side of the prism closer to the light source, and each convex refractive surface is formed on the side of the prism closer to the illumination target plane. Thus, the concave refractive surface is an incident surface, and the convex refractive surface is an emergent surface. Such an arrangement is advantageous in reducing the size of a spot generated by the refracting actions of the refractive surfaces.

However, a more compact optical system can be constituted by arranging the pyramidal concave refractive surface on the side of the prism closer to the illumination target plane and forming that prism to be integral with the prism having the conical concave refractive surface. In other words, the side on which the refractive surface is arranged is not necessarily limited to that illustrated in the first exemplary embodiment.

In the first exemplary embodiment, the second subunit comprising the prism 3b having the conical convex refractive surface and the prism 4b having the pyramidal convex refractive surface is movable in the direction of the optical axis of the illumination optical system such that the interval (relative distance) between the second subunit and the first subunit, which comprises, the prism 3a having the conical concave refractive surface and the prism 4a having the pyramidal concave refractive surface, is variable.

Although two pairs of concave and convex refractive surfaces are used, zooming is performed only by a single operation and a comparatively compact optical system is realized.

The shape of the effective light source formed by the prism unit 2 in the first exemplary embodiment will now be described with reference to FIGS. 4A, 4B and 4C. FIGS. 4A, 4B and 4C illustrate the case where a quadruple beam 26 enters the prism unit 2 wherein poles 26b are positioned about optical axis 26a. As described above, the pair of prisms 3a and 3b each having the conical refractive surface and the pair of prisms 4a and 4b each having the pyramidal refractive surface have an effect of increasing the annular ratio with an increase of the interval between the concave refractive surface and the convex refractive surface. Accordingly, as the interval between the first subunit and the second subunit increases, the above-mentioned effects of the two pairs of the refractive surfaces are additively developed and the annular ratio is increased correspondingly.

On the other hand, when the distance between the concave refractive surface and the convex refractive surface is increased, the pair of conical refractive surfaces develops an effect of increasing the opening angle 15, while the pair of pyramidal refractive surfaces develops an effect of reducing the opening angle 15.

Therefore, even when the distance between the first subunit and the second subunit is changed, influences of the pair of conical refractive surfaces and the pair of pyramidal refractive surfaces upon the opening angle 15 are cancelled and an overall change of the opening angle 15 is reduced.

Thus, according to the first exemplary embodiment, the annular ratio can be changed while suppressing the change of the opening angle 15 of the effective light source formed in the pupil plane of the projection optical system 13.

In the first exemplary embodiment described above, the prism 3a having the conical concave refractive surface, the prism 4a having the pyramidal concave refractive surface, the prism 3b having the conical convex refractive surface, and the prism 4b having the pyramidal convex refractive surface are arranged in the order named.

However, even when the four prisms are arranged as a modified example in the order of the prism 3a having the conical concave refractive surface, the prism 4a having the pyramidal concave refractive surface, the prism 4b having the pyramidal convex refractive surface, and the prism 3b having the conical convex refractive surface, an essentially similar effect can also be obtained although a difference is caused in the effective light source distribution.

While the first exemplary embodiment is able to suppress the change of the opening angle 15 smaller, the aperture stop 12 for blocking a part of the light beam can be disposed between the prism unit and the optical integrator in order to further reduce the change of the opening angle 15. The aperture stop 12 can also be disposed on the side of the zoom lens 5 closer to the light source. Although the aperture stop 12 causes a slight loss of light quantity, the opening angle 15 can be held substantially constant.

Second Exemplary Embodiment

A second exemplary embodiment of the present invention will now be described with reference to FIGS. 5A, 5B and 5C. This second exemplary embodiment has the same construction as the first exemplary embodiment of the present invention except that the prism unit 2 is made up of a first subunit comprising the prism 3a having the conical concave refractive surface, a second subunit comprising the prism 4a having the pyramidal concave refractive surface and the prism 3b having the conical convex refractive surface, and a third subunit comprising the prism 4b having the pyramidal convex refractive surface. In the second exemplary embodiment, the second subunit is movable in the direction of the optical axis of the illumination optical system.

An effective light source formed in the second exemplary embodiment is illustrated in FIGS. 5A, 5B and 5C. FIGS. 5A, 5B and 5C illustrate the case where a circular beam 27 enters the refractive surface. As illustrated in FIG. 5B, poles 27b are positioned about optical axis 27a. Moreover, when the second subunit is positioned closer to the first subunit, the distance between the prisms 3a and 4a having the conical and pyramidal concave refractive surfaces is reduced and the distance between the prisms 3b and 4b having the conical and pyramidal convex refractive surfaces is increased.

On the other hand, as illustrated in FIG. 5C, when the second subunit is positioned closer to the third subunit, the distance between the prisms 3a and 4a having the conical and pyramidal concave refractive surfaces is increased and the distance between the prisms 3b and 4b having the conical and pyramidal convex refractive surfaces is reduced.

As described above, in each of the pair of conical refractive surfaces and the pair of pyramidal refractive surfaces, as the distance between the concave refractive surface and the convex refractive surface increases, the annular ratio is increased. In the second exemplary embodiment, when the distance between one pair of refractive surfaces is increased with zoom-moving of the second subunit, the distance between the other pair of refractive surfaces is reduced. As a result, changes of the annular ratio are canceled and maintained small. Regarding the opening angle 15, as the interval between the concave refractive surface and the convex refractive surface increases, the opening angle 15 is increased in the case of the conical refractive surfaces, but it is reduced in the case of the pyramidal refractive surfaces. Accordingly, influences of the two pairs of conical and pyramidal refractive surfaces upon the opening angle are additively generated with the movement of the second subunit.

Thus, when the second subunit is positioned close to the first subunit, the opening angle 15 is reduced, and when the second subunit is positioned close to the third subunit, the opening angle 15 is increased. Consequently, according to the second exemplary embodiment, the opening angle 15 can be changed while maintaining small the change of the annular ratio of the effective light source.

In the illustrated second exemplary embodiment, the second subunit comprises two prisms, i.e., the prism 4a having the pyramidal concave refractive surface and the prism 3b having the conical convex refractive surface. However, a more compact optical system can be constituted by forming opposite surfaces of a single prism to serve as the pyramidal concave refractive surface and the conical convex refractive surface, respectively.

The above-described exemplary embodiments are illustrated such that each refractive surface has an apex positioned near the optical axis. However, a more compact optical system can be constituted by chamfering a part of the refractive surface near the apex thereof so as to reduce the thickness of the prism having the relevant refractive surface in the direction of the optical axis.

Also, while the exemplary embodiments have been described above in connection with the case that a circular light beam enters the refractive surface, a light beam having an annular shape or a multipole shape can also be introduced by using, e.g., a diffraction optical element. In such a case, the degree of freedom in forming the effective light source distribution is further increased. In other words, the effective light source can be formed in a more variety of shapes.

According to the exemplary embodiments described above, the shape of the effective light source can be adjusted while suppressing a reduction of illumination efficiency. Further, by adjusting the positions of the subunits constituting the prism unit, one of the annular ratio and the opening angle of the effective light source can be changed while suppressing a change of the other.

Other Exemplary Embodiments

An exemplary embodiment of a device manufacturing method utilizing the foregoing exposure apparatus will now be described with reference to FIGS. 6 and 7.

FIG. 6 is a flowchart for explaining a process of manufacturing a device (e.g., a semiconductor chip including IC and LSI, for example, as well as LCD or CCD). The manufacturing of the semiconductor chip will be described here by way of example. In step 1 (circuit design), circuit design of a semiconductor device is performed. In step 2 (mask fabrication), a mask is fabricated based on the designed circuit pattern. In step 3 (wafer production), a wafer (substrate) is produced by using silicon or some other suitable material. In step 4 (wafer process), which is also called a front-end process, an actual circuit is formed on the wafer by the above-described exposure apparatus based on the lithography technique using the mask and the wafer. In step 5 (assembly), which is also called a back-end process, the semiconductor device is manufactured in the form of a chip by using the wafer obtained in step 4. The back-end process includes an assembly step (dicing and bonding), a packaging step (chip encapsulation), and so on. In step 6 (inspection), inspection including an operation check test and a durability test, for example, is made on the semiconductor device manufactured in step 5. After the semiconductor device is completed through the above-described steps, the completed semiconductor device is shipped (step 7).

FIG. 7 is a detailed flowchart of the wafer process in step 4. In step 11 (oxidation), the wafer surface is oxidized. In step 12 (CVD), an insulation film is formed on the wafer surface. In step 13 (electrode formation), electrodes are formed on the wafer. In step 14 (ion implantation), ions are implanted into the wafer. In step 15 (resist process), a photoresist is coated on the wafer. In step 16 (exposure), the circuit pattern on the mask is transferred to the wafer by exposure using the exposure apparatus. In step 17 (development), the exposed wafer is developed. In step 18 (etching), the wafer is etched in an area other than the developed resist image. In step 19 (resist stripping), the resist which is not required any more after the etching is removed. By repeatedly performing the above-mentioned steps, the circuit pattern is formed on the wafer in a multiple way.

As many apparently widely different embodiments of the present invention can be made without departing from the sprit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the claims.

The entire disclosure of Japanese Patent Application No. 2006-246590 filed on Sep. 12, 2006 including claims, specification, drawings, and abstract is incorporated herein by reference in its entirety.

Claims

1. An illumination optical system arranged to illuminate an illumination target plane by using light from a light source, the illumination optical system comprising: a prism unit arranged to refract the light;an optical integrator arranged to form a plurality of light sources with light emerging from the prism unit; andan optical system arranged to introduce light emerging from the optical integrator to the illumination target plane,wherein the prism unit includes a pair of conical refractive surface having a conical concave refractive surface and a conical convex refractive surface, and a pair of pyramidal refractive surface having a pyramidal concave refractive surface and a pyramidal convex refractive surface, andat least one of the concave refractive surface of the one pair and the convex refractive surface of the one pair is disposed between the concave refractive surface of the other pair and the convex refractive surface of the other pair.

2. The illumination optical system according to claim 1, wherein assuming that, of the prism unit, a prism subunit including the conical concave refractive surface and the pyramidal concave refractive surface is a first subunit and a prism subunit including the conical convex refractive surface and the pyramidal convex refractive surface is a second subunit, at least one of the first subunit and the second subunit is movable in a direction of an optical axis of the illumination optical system such that an interval between the first subunit and the second subunit is variable.

3. The illumination optical system according to claim 1, wherein assuming that, of the prism unit, a prism subunit including the conical concave refractive surface is a first subunit, a prism subunit including the pyramidal concave refractive surface and the conical convex refractive surface is a second subunit, and a prism subunit including the pyramidal convex refractive surface is a third subunit, the second subunit is disposed between the first subunit and the third subunit and is movable in a direction of an optical axis of the illumination optical system.

4. The illumination optical system according to claim 3, wherein the second subunit includes a prism having the pyramidal concave refractive surface formed in an incident surface thereof and the conical convex refractive surface in an emergent surface thereof.

5. The illumination optical system according to claim 1, wherein the conical concave refractive surface and the pyramidal concave refractive surface are disposed on a side closer to the light source, and the conical convex refractive surface and the pyramidal convex refractive surface are disposed on a side closer to the illumination target plane.

6. The illumination optical system according to claim 1, wherein an aperture stop blocking a part of the light emerging from the prism unit is disposed in the optical path between the prism unit and the illumination target plane.

7. An exposure apparatus including an illumination optical system arranged to illuminate an illumination target plane by using light from a light source, the illumination optical system including, a prism unit arranged to refract the light;an optical integrator arranged to form a plurality of light sources with light emerging from the prism unit; andan optical system arranged to introduce light emerging from the optical integrator to the illumination target plane,wherein the prism unit includes a pair of conical refractive surface having a conical concave refractive surface and a conical convex refractive surface, and a pair of pyramidal refractive surface having a pyramidal concave refractive surface and a pyramidal convex refractive surface, andat least one of the concave refractive surface and the convex refractive surface of the one pair is disposed between the concave refractive surface of the other pair and the convex refractive surface of the other pair,wherein the illumination optical system is arranged to illuminate an original; anda projection optical system arranged to project an image of a pattern of the original onto a substrate.

8. A device manufacturing method which utilizes an exposure apparatus including an illumination optical system arranged to illuminate an illumination target plane by using light from a light source, the illumination optical system including, a prism unit arranged to refract the light;an optical integrator arranged to form a plurality of light sources with light emerging from the prism unit; andan optical system arranged to introduce light emerging from the optical integrator to the illumination target plane,wherein the prism unit includes a pair of conical refractive surface having a conical concave refractive surface and a conical convex refractive surface, and a pair of pyramidal refractive surface having a pyramidal concave refractive surface and a pyramidal convex refractive surface, andat least one of the concave refractive surface and the convex refractive surface of the one pair is disposed between the concave refractive surface of the other pair and the convex refractive surface of the other pair,wherein the illumination optical system is arranged to illuminate an original; anda projection optical system arranged to project an image of a pattern of the original onto a substrate;the method including:exposing a substrate by using the exposure apparatus; anddeveloping the substrate.