INSTRUMENT FOR MEASURING THE ANGULAR DISTRIBUTION OF LIGHT PRODUCED BY AN ILLUMINATION SYSTEM OF A MICROLITHOGRAPHIC PROJECTION EXPOSURE APPARATUS

Abstract

Instruments (as well as related components and methods) to measure the angular distribution of light produced by an illumination system of a microlithographic projection exposure apparatus are disclosed. Such apparatusus are used for the production of integrated circuits and other microstructured components.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Various features and advantages of the present disclosure may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawing in which:

FIG. 1 is a perspective and considerably simplified view of a projection exposure apparatus;

FIG. 2 is a meridional section through an illumination system contained in the projection exposure apparatus shown in FIG. 1;

FIG. 3 is an enlarged meridional section through an instrument;

FIG. 4 is a top view on a CCD image sensor showing different polarization directions;

FIG. 5 is a top view on a CCD image sensor similar to FIG. 4, but showing other polarization directions;

FIG. 6 is an enlarged meridional section through an instrument in a first operational state; and

FIG. 7 is an enlarged meridional section through the instrument of FIG. 7 in a second operational state.

DETAILED DESCRIPTION

By way of introduction, the general structure of a microlithographic projection exposure apparatus, and in particular of its illumination system, will be explained. This is because it is believed that certain aspects of the disclosure can be fully appreciated only if the technological environment where the instrument is used is thoroughly understood.

1. General Structure of Projection Exposure Apparatus

FIG. 1 is a perspective and highly simplified view of a projection exposure apparatus 10 that comprises an illumination system 12 for producing a projection light bundle. The projection light bundle illuminates a field 14 on a mask 16 containing minute structures 18. In this embodiment, the illuminated field 14 has approximately the shape of a ring segment. However, other, for example rectangular, shapes of the illuminated field 14 are contemplated as well.

A projection objective 20 images the structures 18 within the illuminated field 14 onto a light sensitive layer 22, for example a photoresist, which is deposited on a substrate 24. The substrate 24, which may formed by a silicon wafer, is arranged on a wafer stage (not shown) such that a top surface of the light sensitive layer 22 is precisely located in the image plane of the projection objective 20. The mask 16 is positioned via a mask stage (not shown) in an object plane of the projection objective 20. Since the latter has a magnification of less than 1, a reduced image 14′ of the structures 18 within the illuminated field 14 is formed on the light sensitive layer 22.

2. General Structure of Illumination System

FIG. 2 is a more detailed meridional section through the illumination system 12 shown in FIG. 1. For the sake of clarity, the illustration of FIG. 2 is also considerably simplified and not to scale. This particularly implies that different optical units are represented by very few optical elements only. In reality, these units may comprise significantly more lenses and other optical elements.

The illumination system 12 comprises a housing 28 and a light source that is, in the embodiment shown, realized as an excimer laser 30. The excimer laser 30 emits projection light that has a wavelength of about 193 nm. Other types of light sources and other wavelengths, for example 248 nm or 157 nm, are also contemplated.

In the embodiment shown, the projection light emitted by the excimer laser 30 enters a beam expansion unit 32 in which the light bundle is expanded. After passing through the beam expansion unit 32, the projection light impinges on a first optical raster element 34. The first optical raster element 34 slightly increases the geometrical optical flux and modifies the local irradiance distribution in a subsequent pupil plane.

The first optical raster element 34 is positioned in an object plane 42 of an objective 44 that comprises a zoom lens group 46 and a pair 48 of axicon elements 50, 52 having opposing conical faces. If both axicon elements 50, 52 are in contact, as is shown in FIG. 2, the axicon pair 48 has the effect of a plate having parallel plane surfaces. If both elements 50, 52 are moved apart, the spacing between the axicon elements 50, 52 results in a shift of light energy radially outward. Since axicon elements are known as such in the art, these will not be explained here in further detail.

Reference numeral 54 denotes an exit pupil plane of the objective 44. An optical integrator 56 producing secondary light sources is positioned in or in close proximity to the exit pupil plane 54 of the objective 44. The optical integrator 56 modifies the angular distribution in the pupil plane 54. The angular distribution in the pupil plane 54 directly translates into an irradiance distribution in a subsequent field plane. Thus the design of the optical integrator 56 has a strong influence on the irradiance distribution and the geometry of the illuminated field 14 on the mask 16. The angular distribution of the light on the mask 16, however, is directly related to the spatial irradiance distribution of the light in the pupil plane 54. This spatial irradiance distribution is mainly determined by the first optical raster element 34 and the positions of the elements contained in the objective 44.

The projection light emerging from the secondary light sources enters a condenser 62 that is represented in FIG. 2 by a single lens element for the sake of simplicity. The entrance pupil plane of the condenser 62 coincides with the exit pupil plane 54 of the objective 44. The condenser 62 superposes the light bundles emitted by the secondary light sources in a field stop plane 64 of the condenser 62 in which a field stop 66 is positioned. A field stop objective 68 images the field stop 66 onto a mask plane 70 in which the mask 16 is positioned during exposure operation, as it has been shown in FIG. 1.

3. Angular Distribution of Light

At the bottom of FIG. 2 three light bundles are indicated each converging to one of three points 721, 722 and 723 which are arranged in the mask plane 70 within the illuminated field 14. For the sake of simplicity it is assumed that the light bundles are formed only by the light rays that are represented by the (broken) lines shown in FIG. 2. Each light ray impinges on the mask plane 70 with a certain angle of incidence. The totality of light rays contained in a single bundle defines an angular distribution which is associated to the point to which the light rays converge. In this schematic illustration it is assumed that the angular distribution is the same for all points 721, 722, 723.

4. Measuring Instrument

In order to measure the angular distribution of light converging to one of the points 721, 722 and 723, an instrument 80 is provided which has a small pinhole 82. During the measurement the pinhole 82 is arranged at the point in the mask plane 70 where the angular distribution is to be measured. In FIG. 2 this is assumed to be point 721.

FIG. 3 shows an enlarged meridional section through the instrument 80. The pinhole 82 is formed by a small circular aperture formed in an opaque lid 84. The lid 84 covers a housing 86 which is completely opaque as well. Therefore light can enter into the inside of the instrument 80 only through the pinhole 82.

Along an optical axis 88 of the instrument 80 running through the pinhole 82 a positive aspherical lens 90, a quarter-wave plate 92 supporting an attenuation layer 94 and an irradiance sensor 96 are arranged. Since the pinhole 82 is located in the mask plane 70, the light bundle converging to the point 721 diverges inside the instrument 80. The aspherical surface of the positive lens 90 is determined such that the light bundle is, even for the rays 110a, 110d having larger angles of incidence, perfectly collimated before it impinges on the quarter-wave plate 92. As the quarter-wave plate 92 has plane and parallel surfaces that are aligned perpendicular to the optical axis 88, the light impinging on the irradiance sensor 96 is still collimated. The attenuating layer 94 causes an irradiance offset and ensures that the irradiance sensor 96 does not run into saturation.

The irradiance sensor 96 is, in the embodiment shown, realized as a CCD image chip that has a square base surface 98, which is mounted to a support 104, and four edges. Two of these edges, which will be referred to in the following as side edges, are denoted in FIG. 3 by 100, 102. The irradiance sensor 96 contains a grid of pixels each being sensitive to radiation. The signal produced by each pixel is a measure for the light energy impinging on the pixel during a certain (short) time interval. From this signal it is possible to determine the irradiance (light energy per unit area per unit time) at the respective pixel. As will be explained further below, the pixels of the irradiance sensor 96 have a polarization dependent sensitivity.

Since angles in the mask plane 70 of the light rays translate into positions in the sensor plane where the pixels are arranged, the irradiance distribution detected by the sensor 96 is used to determine the angular distribution of the light at point 721 in the mask plane 70. This determination is known in the art as such.

A high-precision stage (not shown) may be provided for moving the instrument 80 with its pinhole 82 to different positions within the illuminated field 14 in the mask plane 70. The movement is indicated in FIG. 2 by a double arrow 106. This makes it possible to measure, for a large plurality of different points in the mask plane 70, the angular distribution of the light produced by the illumination system 12 without the necessity to adjust the position of the instrument 80 for each individual measurement.

In the following it is assumed that two out of four light rays 110a, 110b, 110c and 110d entering the instrument 80 through the pinhole 82 are linearly polarized with a first polarization direction being parallel along the front and rear edges of the sensor 96, i.e. parallel to the extension of the sheet of FIG. 3. The polarization direction of these two light bundles 110a, 110d is indicated in FIG. 3 by double arrows indicated by P1. The other two rays 110b, 110c are in an orthogonal state of polarization, i.e. with a polarization direction parallel to the side edges 100, 102 of the irradiance sensor 96. This polarization direction is indicated in FIG. 3 by dots P2.

FIG. 4 shows a top view on the irradiance sensor 96 in which the orientation of the optic axis 112 of the quarter-wave plate 92 is indicated by a dot-dash line. The optic axis 112 forms an angle of 45° with respect to the side edges 100, 102 of the irradiance sensor 96. As a result of this orientation of the optic axis, the quarter-wave plate 92 converts both linear states of polarization P1, P2 of the light rays 110a to 110d into circular states of polarization, as is indicated by circles P_c in FIGS. 3 and 4. Thus the light rays 110a to 110d impinge on the irradiance sensor 96 without having a dominant polarization direction.

This ensures that light rays having the same intensity but a different linear state of polarization produce the same irradiance signal at the pixels of the irradiance sensor 96 where the light rays impinge. Without the quarter-wave plate 92, the light rays 110a to 110d would impinge on the irradiance sensor 96 with different linear states of polarization. Since the pixels of the irradiance sensor 96 have a polarization dependent sensitivity, this would result in different values for the measured irradiance even if the intensity of the light is identical. Usually the pixels have a sensitivity which is different for light being linearly polarized along the direction P1, which is parallel to the side edges 100, 102 on the one hand, and for light being linearly polarized along the direction P2 which is parallel to the front and rear edges 101, 103 (see FIG. 4) of the irradiance sensor 96. Thus different irradiances would be measured for the light rays 110a, 110d on the one hand and the light rays 110b, 110c on the other hand if all rays have the same intensity. Due to the provision of the quarter-wave plate 92, however, the light impinging on the irradiance sensor 96 is circularly polarized, and thus the different sensitivities of the pixels for the two orthogonal polarization directions P1, P2 do not matter.

If light rays are impinging on the quarter-wave plate 92 that are linearly polarized along the optic axis 112 or perpendicular thereto, as is shown in the top view of FIG. 5, the quarter-wave plate 92 does not have any effect on the polarization, because these are eigenstates of the quarter-wave plate 92. Although such light rays have a dominant polarization direction when they impinge on the irradiance sensor 96, there is no dominant polarization component along the directions P1 and P2 where the maximum sensitivity difference occurs. Thus the different sensitivities of the irradiance sensor 96 for the different states of polarization do not matter.

Apparently the quarter-wave plate 90 does not produce light having a dominant polarization component along the edges 100, 101, 102, 103 irrespective of the polarization direction of the light impinging thereon. This may be easily understood if the polarization direction of the impinging light is decomposed into a component being parallel to the direction P1 and a component parallel to the optic axis 112. The component being parallel to the direction P1 is converted by the quarter-wave plate 92 into a circular state of polarization, whereas the component parallel to the optic axis 112 is not changed. A superposition of these two states of polarization results in an elliptical state of polarization in which the longer main axis (i.e. dominant direction) is parallel to the optic axis 112. As a result, the pixels of the irradiance sensor 96 will measure the same irradiance irrespective of the polarization direction of the light passing through the pinhole 82.

FIG. 6 shows a meridional section through an instrument 80′. For like parts the same reference numerals as in FIG. 3 are used. The instrument 80′ differs from the instrument 80 shown in FIG. 3 mainly in that the quarter-wave plate 92 is replaced by a polarizer 130 that linearly polarizes light propagating therethrough. The polarizer 130 is mounted in this embodiment so as to be rotatable around the optical axis 88, as is indicated in FIG. 6 by a double arrow 132. The polarizer 130 may also be provided with an attenuating layer 94 attached to one of its surfaces.

In FIG. 6 the polarizer 130 is shown in a first angular position in which only the light rays 110a, 110d being polarized along the direction P1 are allowed to pass through the polarizer 130. Thus the irradiance sensor 96 detects only those components of the impinging light which have a linear polarization direction parallel to the front and rear edges 101, 103.

If the polarizer 130 is rotated by 90°, or replaced by another polarizer having an orthogonal polarization direction, the light rays 110a, 110d are blocked, and now the light rays 110b, 110c being polarized along the direction P2 are allowed to pass through the polarizer 130. This is shown in FIG. 7. Now the irradiance sensor 96 detects only those components of the light that have a polarization direction parallel to the side edges 100, 102.

If the sensitivity of the irradiance sensor 96 is different for both polarization directions, it is possible to take this computationally into account if a calibration measurement has been carried out beforehand. During the calibration measurement, the different sensitivities are measured with a similar setup as shown in FIGS. 6 and 7. The only difference is that the light intensity of the rays has to be known. In the simplest case unpolarized light enters through the pinhole 82. The different measurement values obtained with the two different polarization directions obtained with by the polarizer 130 result in correction parameters that are computationally accounted for during subsequent measurements of the angular distribution. For example, the irradiance values measured in the configuration shown in FIG. 7 will be multiplied with a correction parameter that accounts for the different sensitivity of the irradiance sensor 96 for light being linearly polarized along the side edges 100, 102.

Other embodiments are covered by the claims.

Claims

1. An instrument configured to measure an angular distribution of light produced by an illumination system of a microlithographic projection exposure apparatus, the instrument comprising: a) a pinhole,b) a polarization conversion unit configured to convert at least one state of polarization of the light into a circular state of polarization, andc) an irradiance sensor configured to detect the spatial distribution of light having passed the pinhole and the polarization conversion unit.

2. The instrument of claim 1, wherein the polarization conversion unit is configured to introduce a phase shift between two orthogonal states of polarization.

3. The instrument of claim 2, wherein the polarization conversion unit is configured to introduce a phase shift of (2m+1)·90°, m=0, 1, 2, . . . , between two orthogonal states of polarization.

4. The instrument of claim 3, wherein the polarization conversion unit comprises a quarter-wave plate.

5. The instrument of claim 4, wherein the irradiance sensor is configured to display a maximum sensibility difference for light which is linearly polarized along a first direction (P1) and light which is linearly polarized along a second direction (P2) which is orthogonal to the first direction (P1), and wherein the quarter-wave plate comprises a birefringent material having an optic axis that is arranged at 45° to the first direction (P1).

6. The instrument of claim 5, wherein the irradiance sensor is a CCD sensor having two pairs of orthogonal edges, the edges determining the first direction (P1) and the second direction (P2).

7. The instrument of claim 1, wherein the polarization conversion unit is arranged between the pinhole (82) and the irradiance sensor.

8. The instrument of claim 1, further comprising a lens having a positive refractive power which is arranged between the pinhole and the irradiance sensor.

9. The instrument of claim 8, wherein the lens is a collimator lens that converts a diverging light bundle emerging from the pinhole into an at least substantially collimated light bundle.

10. The instrument of claim 9, wherein the polarization conversion unit is arranged between the collimator lens and the irradiance sensor.

11. The instrument of claim 8, wherein the lens is aspherical.

12. An instrument configured to measure an angular distribution of light produced by an illumination system of a microlithographic projection exposure apparatus, the instrument comprising: a) a pinhole,b) a polarizer configured to selectively pass light in one of two distinct linear states (P1, P2) of polarization, andc) an irradiance sensor configured to detect the spatial distribution of light passing the pinhole and being in either of the two linear states (P1, P2) of polarization.

13. The instrument of claim 12, wherein the polarizer is a polarization filter that is mounted so as to be rotatable around an axis which is parallel to an optical axis of the instrument.

14. The instrument of claim 12, wherein the irradiance sensor displays a maximum sensibility difference for light which is in one (P1) of the two linear states of polarization and light which is in the other (P2) of the two linear states of polarization.

15. An instrument configured to measure an angular distribution of light produced by an illumination system of a microlithographic projection exposure apparatus, the instrument comprising: a) a pinhole,b) an aspherical lens, andc) an irradiance sensor that detects the spatial distribution of light after it has passed the pinhole and the lens.

16. A projection exposure apparatus, comprising: an illumination system; andthe instrument of claim 1, wherein the pinhole is arranged at least substantially in an illumination plane of the illumination system where a mask is positioned during exposure operation.

17. A method of measuring an angular distribution of light produced by an illumination system of a microlithographic projection exposure apparatus, the method comprising: a) positioning a pinhole in an illumination plane of the illumination system;b) providing an irradiance sensor that detects a spatial distribution of light having passed the pinhole, wherein the irradiance sensor displays a maximum sensibility difference for light which is in a first linear state of polarization (P1) and light which is in a second linear state of polarization (P2);c) measuring the sensibility of the irradiance sensor for light impinging in the first linear state of polarization (P1);d) measuring the sensibility of the irradiance sensor for light impinging in the second linear state of polarization (P2);e) providing a polarizer that passes light in the first linear states of polarization (P1);f) detecting the spatial distribution of light passing the pinhole and being in the first linear state of polarization (P1);g) providing a polarizer that passes light in the second linear states of polarization (P2);h) detecting the spatial distribution of light passing the pinhole and being in the second linear state of polarization (P2);i) determining the total irradiances for the light impinging on the irradiance sensor in both linear states of polarizations (P1, P2), thereby taking into account the sensibility measured in c) and d).