1. Field of the Invention
The present invention relates to a lithography apparatus and method of forming a pattern on a substrate, and a method of manufacturing an article.
2. Description of the Related Art
Japanese Patent Laid-Open No. 2003-92246 describes an alignment mark including first measurement marks X1, X2, X3, and X4 and second measurement marks Y1 and Y2. The first measurement marks X1, X2, X3, and X4 are used to measure the position of the alignment mark in the X-direction. The second measurement marks Y1 and Y2 are used to measure the position of the alignment mark in the Y-direction. The second measurement marks Y1 and Y2 are arranged outside the region in which the first measurement marks X1, X2, X3, and X4 are arranged, and parallel to the direction in which scribe lines extend. The position of the alignment mark in the X-direction is the average of the positions of the first measurement marks X1, X2, X3, and X4. The position of the alignment mark in the Y-direction is the average of the positions of the second measurement marks Y1 and Y2.
A maximum precision is not always required in both the X- and Y-directions. If, for example, a maximum precision is required in one of the X- and Y-directions, while a precision lower than the maximum precision suffices in the other direction, measurement with the maximum precision in both the X- and Y-directions is disadvantageous in terms of the throughput.
The present invention provides, for example, a lithography apparatus advantageous in terms of throughput.
One of the aspects of the present invention provides a lithography apparatus which positions a substrate based on measurement of a position of an alignment mark formed on the substrate to form a pattern on the substrate, the apparatus comprising: an acquisition unit configured to acquire a first required alignment precision in a first direction, and a second required alignment precision in a second direction different from the first direction; and a controller configured to determine, based on the first required alignment precision, a first condition for a first measurement process of measuring a position of an alignment mark in the first direction, to determine, based on the second required alignment precision, a second condition for a second measurement process of measuring a position of an alignment mark in the second direction, to control execution of the first measurement process in accordance with the first condition, and to control execution of the second measurement process in accordance with the second condition.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
The first embodiment of the present invention will be described with reference to
An exemplary charged particle beam exposure apparatus will be described below with reference to
The intermediate images 209 formed in the vicinities of the blanking apertures 208 are projected onto the substrate 217 set on a substrate stage 218 by a projection system 250 including a first projection lens 210 and second projection lens 214. The projection system 250 is driven by a lens control circuit 222 so as to match the rear focal position of the first projection lens 210 with the front focal position of the second projection lens 214. The electron beams 206 which form the intermediate images 209, respectively, are collectively deflected and positioned by a main deflector 213 and a sub-deflector 215. For example, the deflection width of the main deflector 213 can be set wide, while that of the sub-deflector 215 can be set narrow. An irradiation amount control circuit 221 controls the turning ON/OFF of the electron beams 206 using the blankers, respectively, of the blanking array 207 under the control of a controller 226 based on pattern data. A deflection control circuit 223 controls the deflection operations of the main deflector 213 and sub-deflector 215 under the control of the controller 226 based on the pattern data. A stage control circuit 225 controls the positioning operation of the substrate stage 218 under the control of the controller 226 based on the pattern data. A pattern is drawn on the substrate 217 upon the ON/OFF control of the electron beams 206 using the blankers, respectively, of the blanking array 207, the control of the deflection operations of the main deflector 213 and sub-deflector 215, and the control of the positioning operation of the substrate stage 218 using the stage control circuit 225. The controller 226 can be connected to a computer 200 which supplies drawing data to the controller 226.
A position measurement mark 227 and a Faraday cup 219 are arranged on the substrate stage 218. An electron detector 216 is arranged above the substrate stage 218. A signal detected by the electron detector 216 is processed by a signal processing circuit 224 to detect the amount of the electron beam.
The controller 226 can be connected to the computer 200 which supplies drawing data to the controller 226, and a console 240 which allows input of various types of data to the controller 226. The controller 226 includes an acquisition unit 280 and measurement process control unit 260. The acquisition unit 280 acquires a first required alignment (overlay) precision in the X-direction (first direction), and a second required alignment (overlay) precision in the Y-direction (second direction) different from the X-direction (first direction). Note that the first and second directions can be different directions (two directions), which are typically orthogonal to each other.
The controller 226 can acquire first and second required alignment precisions from the computer 200 or console 240. The measurement process control unit 260 determines a first condition for a first measurement process of detecting the position of an alignment mark in the X-direction, based on the first required alignment precision. The measurement process control unit 260 also determines a second condition for a second measurement process of detecting the position of an alignment mark in the Y-direction, based on the second required alignment precision. The measurement process control unit 260 then controls execution of the first measurement process in accordance with the first condition, and controls execution of the second measurement process in accordance with the second condition. The measurement process control unit 260 can determine a first condition based on the first required alignment precision, and a second condition based on the second required alignment precision by looking up, for example, a table 270. The table 270 can include, for example, a plurality of required alignment precisions of different levels, and a plurality of conditions (conditions for measurement processes) corresponding to the plurality of required alignment precisions of different levels, respectively.
The operation of the exposure apparatus and an exposure method in the first embodiment will be described below with reference to
In step S506, the measurement process control unit 260 determines a first condition for a first measurement process of detecting the position of the alignment mark 25 in the X-direction, based on the first required alignment precision acquired by the acquisition unit 280. In step S506, the measurement process control unit 260 also determines a second condition for a second measurement process of detecting the position of the alignment mark 26 in the Y-direction, based on the second required alignment precision acquired by the acquisition unit 280. Although the acquisition unit 280 acquires first and second required alignment precisions at arbitrary timings, it can acquire these precisions at, for example, the start of the process shown in
In step S508, the measurement process control unit 260 executes fine alignment measurement using the alignment marks 25 and 27 in accordance with the first and second conditions determined in step S506. That is, the measurement process control unit 260 controls execution of the first measurement process in accordance with the first condition, and controls execution of the second measurement process in accordance with the second condition. In the first and second measurement processes, the alignment marks 25 and 27 are observed through the alignment scope 22, and the position of the alignment mark 25 in the X- and Y-directions is determined by the processor 41. Such a process is executed for pluralities of alignment marks 25 and 27.
In step S510, the substrate 217 is exposed to light while being aligned based on the result of the fine alignment measurement (the positions of the alignment marks 25 and 27). Note that the parallel eccentricities, rotations, and magnifications of all shot regions formed on the substrate 217 can be calculated by statistically processing the measurement results of the positions of the pluralities of alignment marks 25 and 27 obtained in step S508. A method of performing alignment upon calculating such information is called global alignment. In this case, one or more alignment marks 25 and one or more alignment marks 27 can be formed on scribe lines in each shot region.
A practical example of the first measurement process based on the first condition, and the second measurement process based on the second condition will be given below. Let √a:1 be the ratio between the first required alignment precision in the X-direction (first direction) and the second required alignment precision in the Y-direction (second direction). Also, let nx be the number of alignment marks 25 used for position detection in the X-direction, and ny be the number of alignment marks 27 used for position detection in the Y-direction. Then, we have:
√a:1=√nx:√ny (1)
This means that as the number of alignment marks used for position detection increases, the position detection precision improves, so the alignment precision also improves. Note that the alignment precision is, for example, the reciprocal of the alignment error, and becomes better as its numerical value increases. Similarly, the position detection precision is, for example, the reciprocal of the position detection error, and becomes better as its numerical value increases.
In the first embodiment, the ratio between the numbers of alignment marks 25 and 27 used for position detection is determined as the first and second conditions based on equation (1). Typically, the number of alignment marks in one of the X- and Y-directions, in which a higher alignment precision is required, is determined by process optimization, and the number of alignment marks in the other direction is determined in accordance with equation (1). Alternatively, the number of alignment marks in one of the X- and Y-directions, in which a higher alignment precision is required, may be determined to be sufficiently large based on an empirical rule, and the number of alignment marks in the other direction may be determined in accordance with equation (1). In this case, the alignment precisions of the exposed substrate can be evaluated, and the number of alignment marks in one of the X- and Y-directions, in which a higher alignment precision is required, can be changed based on the evaluation result. In response to this, the number of alignment marks in the other direction can be determined in accordance with equation (1).
As described above, in the first embodiment, the measurement process control unit 260 determines a first condition in the X-direction based on the first required alignment precision in the X-direction, and a second condition in the Y-direction based on the second required alignment precision in the Y-direction. By individually determining a first condition for alignment (or position detection) in the X-direction, and a second condition for alignment (or position detection) in the Y-direction in this way, the throughput can be improved while the required alignment precisions are satisfied.
A practical example will be given below with reference to
√12:√6=√2:1 (2)
Although the alignment marks 25 and 27 are formed in each shot region in an example shown in
The first embodiment is also applicable to alignment of a substrate 217 on which alignment marks 28 as illustrated in
Note that an example of a process in which different required alignment precisions are set in the X- and Y-directions is cutting lithography. As another, more common example, the required alignment precisions in the X- and Y-directions are determined based on, for example, the shape of a circuit pattern, and are generally different from each other.
The second embodiment of the present invention will be described below. Details which are not particularly referred to herein can be the same as in the first embodiment. In the second embodiment, a measurement process control unit 260 determines the count of reception of the pieces of information of alignment marks used for alignment in the X-direction using an alignment scope 22, based on the first required alignment precision. The measurement process control unit 260 also determines the count of reception of the pieces of information of alignment marks used for alignment in the Y-direction using the alignment scope 22, based on the second required alignment precision. Note that the alignment marks used for alignment in the X-direction, and the alignment marks used for alignment in the Y-direction may be the same as or different from each other.
A practical example will be given below with reference to
The positions of peaks Px1, Px2, Px3, and Px4 in the detection signal illustrated in
X_position=(Px1+Px2+Px3+Px4)/4 (3)
The processor 41 performs operations including control of a driving unit included in the alignment scope 22, ON/OFF control of a light source, and processing of a detection signal. A detection signal can be processed based on measurement process parameters in that case. These measurement process parameters can include parameters for controlling the operation of the photoelectric converter. The processor 41 can be configured to receive a plurality of detection signals (these signals are updated continually) output from the photoelectric converter, calculate X position in accordance with equation (3) based on each received detection signal, and average the calculation results, thereby obtaining the final value of X_position. This means that the processor 41 is configured to measure the position of each individual alignment mark 25 a plurality of times, and average a plurality of measurement results obtained by the repetitions of measurement, thereby detecting the position of the alignment mark 25. With this operation, detection errors included in the detection signals due to minute vibration of a substrate stage 218, and detection errors due, for example, to electrical noise can be reduced by an averaging effect.
The positions of peaks Py1, Py2, Py3, and Py4 in the detection single illustrated in
Y_position=(Py1+Py2+Py3+Py4)/4 (4)
The processor 41 can be configured to receive a plurality of detection signals (these signals are updated continually) output from the photoelectric converter, calculate Y position in accordance with equation (4) based on each received detection signal, and average the calculation results, thereby obtaining the final value of Y_position. This means that the processor 41 is configured to measure the position of each individual alignment mark 27 a plurality of times, and average a plurality of measurement results obtained by the repetitions of measurement, thereby detecting the position of the alignment mark 27.
As the measurement count of each individual alignment mark to be averaged increases, the position detection precision of this alignment mark improves and, eventually, the alignment precision also improves. Hence, the measurement process control unit 260 determines the measurement count of each individual alignment mark 25 in detecting the position of this alignment mark 25 in the X-direction, based on the first required alignment precision in the X-direction. Similarly, the measurement process control unit 260 determines the measurement count of each individual alignment mark 27 in detecting the position of this alignment mark 27 in the Y-direction, based on the second required alignment precision in the Y-direction.
Assume herein that upon expression of the alignment precisions as size errors, the first required alignment precision (size error) in the X-direction is 1/n the second required alignment precision (size error) in the Y-direction. In this case, the measurement count for averaging in the X-direction is preferably n2 times that for averaging in the Y-direction. For example, the measurement reproducibility precision (size error) of the alignment scope 22 is assumed to be 100 nm. Also, the second required alignment precision (size error) in the Y-direction is assumed to be 100 nm, and the first required alignment precision (size error) in the X-direction is assumed to be two times stricter than in the Y-direction, that is, 50 nm. In this case, when the measurement count in the Y-direction is 1, and the measurement count in the X-direction is 22=4, measurement can be done while a first required alignment precision (size error) of 100 nm/4=50 nm is satisfied.
The charge accumulation time taken for the photoelectric converter of the alignment scope 22 to acquire the information of each individual alignment mark by photoelectric conversion also influences the position detection precision (and, eventually the alignment precision). Prolonging the charge accumulation time makes it possible to average minute fluctuations in the detection signals due to the influence of minute vibration of the substrate stage 218 or disturbance, thereby reducing detection errors. Hence, the measurement process control unit 260 may determine the charge accumulation time taken for the photoelectric converter to acquire the pieces of information of the alignment marks 25 in the X-direction, based on the first required alignment precision in the X-direction. Similarly, the measurement process control unit 260 may determine the charge accumulation time taken for the photoelectric converter to acquire the pieces of information of the alignment marks 27 in the Y-direction, based on the second required alignment precision in the Y-direction. Assume herein that upon expression of the alignment precisions as size errors, the first required alignment precision (size error) in the X-direction is 1/n the second required alignment precision (size error) in the Y-direction. In this case, the charge accumulation time taken to detect the positions of the alignment marks in the X-direction is preferably n2 times that taken to detect the positions of the alignment marks in the Y-direction.
The third embodiment of the present invention will be described with reference to
The fourth embodiment of the present invention will be described with reference to
A method of manufacturing an article according to an embodiment is suitable for manufacturing various articles including a microdevice such as a semiconductor device and an element having a microstructure. This method can include a step of forming a pattern (for example, a latent image pattern) on an object (for example, a substrate having a photosensitive material applied on its surface) using the above-mentioned lithography apparatus, and a step (for example, a development step) of processing the object having the pattern formed on it in the forming step. This method can also include subsequent known steps (for example, oxidation, film formation, vapor deposition, doping, planarization, etching, resist removal, dicing, bonding, and packaging). The method of manufacturing an article according to this embodiment is more advantageous in terms of at least one of the performance, quality, productivity, and manufacturing cost of an article than the conventional methods.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
Note that alignment marks 25 and 27 may be a (two dimensional) mark (such as a mark 251 shown in
This application claims the benefit of Japanese Patent Application No. 2011-272748 filed Dec. 13, 2011 and No. 2012-260341 filed Nov. 28, 2012, which are hereby incorporated by reference herein in their entirety.
Number | Date | Country | Kind |
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2011-272748 | Dec 2011 | JP | national |
2012-260341 | Nov 2012 | JP | national |