The invention relates to a method and apparatus for producing with a gas discharge laser an output laser beam comprising output laser light pulses, for delivery as a light source to a utilizing tool is disclosed.
Applicants have discovered that vertical symmetry can be a problem with certain laser light sources, e.g., gas discharge laser lithography light sources, e.g., XLA series lasers sold by applicants' assignee Cymer, Inc. for use in integrated circuit lithography. The vertical profile centroid may shift depending on laser operating conditions. Also at issue in such light sources is beam coherence.
The use of a spinning diffuser for spatial coherence destruction is a common technique for certain applications where spatial coherence is undesirable, though applicants are not aware of its use as applied in the present application, since applicants believe they are the first to discover the nature of the problem impacting, e.g., the high speed measurement of spectral energy integration values for high repetition rate pulsed narrow band gas discharge lasers utilizing, e.g., fringe width measurements at some selected width at some selected percentage of the peak value, e.g., full width at half the maximum (“FWHM”) with accuracies required in the tens of femtometers at repetition rates in the thousands of pulses per second, e.g., at and well above 2000 pulses per second. applicants have determined that such measurements, i.e., FWHM and the like are adversely affected by speckle of these dimensions of the FWHM measurements.
The requirements from integrators of laser light sources into steppers and scanners and like lithography tools are ever continuing to tighten, and next generation laser light sources, e.g., will have to address a variety of operational requirements to meet the customer demands, e.g., in the operation of the wavemeters, e.g., at higher speeds for pulse to pulse measurements or some acceptable substitute that trades accuracy for pulse to pulse measurement and with the greater accuracy and consistency required, e.g., for accurate E95 measurements at the tens of femtometer levels.
Pulse stretchers are known in the art, e.g., as disclosed in U.S. Pat. No. 6,535,531, issued on Mar. 18, 2003 to Smith et al., entitled GAS DISCHARGE LASER WITH PULSE MULTIPLIER, based on an application Ser. No. 10/006,913, filed on Nov. 29, 2001. U.S. Pat. No. 6,480,275, issued on Nov. 12, 2002, to Sandstrom et al., entitled HIGH RESOLUTION ETALON-GRATING MONOCHROMATOR, based on an application Ser. No. 09/772,293 Jan. 29, 2001, filed on shows a etalon/grating based monochromator used for spectrometry.
A method and apparatus for producing with a gas discharge laser an output laser beam comprising output laser light pulses, for delivery as a light source to a utilizing tool is disclosed which may comprise a beam path and a beam homogenizer in the beam path. The beam homogenizer may comprise at least one beam image inverter or spatial rotator, which may comprise a spatial coherency cell position shifter. The homogenizer may comprise a delay path which is longer than, but approximately the same delay as the temporal coherence length of the source beam. The homogenizer may comprise a pair of conjoined dove prisms having a partially reflective coating at the conjoined surfaces of each, a right triangle prism comprising a hypotenuse face facing the source beam and fully reflective adjoining side faces or an isosceles triangle prism having a face facing the source beam and fully reflective adjoining side faces or combinations of these, which may serve as a source beam multiple alternating inverted image creating mechanism. The beam path may be part of a bandwidth detector measuring the bandwidths of an output laser beam comprising output laser light in the range of below 500 femtometers at accuracies within tens of femtometers. The homogenizer may comprise a rotating diffuser which may be a ground glass diffuser which may also be etched. The wavemeter may also comprise a collimator in the beam path collimating the diffused light; a confocal etalon creating an output based upon the collimated light entering the confocal etalon; and a detector detecting the output of the confocal etalon and may also comprise a scanning mechanism scanning the angle of incidence of the collimated light entering the confocal etalon which may scan the collimated light across the confocal etalon or scan the etalon across the collimated light, and may comprise an acousto-optical scanner. The confocal etalon may have a free spectral range approximately equal to the E95 width of the input source spectrum to be measured. The detector may comprise a photomultiplier detecting an intensity pattern of the output of the confocal etalon.
FIGS. 5B1-B7 shows schematically aspects of the operation of a wavementer according to
To alleviate the problem of loss of beam symmetry, e.g., vertical symmetry, e.g., where the vertical centroid tends to shift, applicants propose, e.g., the use of any of a variety of multiple optical schemes that can produce alternating inverted images of the beam. Applicants believe that such schemes will not only positively affect beam profile symmetry but also have a beneficial impact on the spatial coherence of the beam, since by there intrinsic behavior such optics can, e.g., shift the position of coherence cells.
Upon examination it was discovered by applicants in the testing of the properties of a 100 ns optical pulse stretcher (“OPuS”) as discussed in the above reference co-pending patent applications also assigned to applicants' assignee, that beam symmetry can be improved when optics such as those contained in an OPuS module are inserted into the laser output beam path. This effect was attributed by applicants to the imaging characteristics of, e.g., the optics in the 100 ns OPuS.
Also noted by applicants was that, e.g., if a pulse stretcher contained an odd number of image relays it would create an inverted image of the input beam. Since the entire pulse stretcher creates a pulse train from an original input pulse, each sub-pulse will be an inverted image from the previous sub-pulse. Therefore, the original input beam pulses will be converted into a series of sub-pulses whose beam profiles will have alternating inverted images. Applicants propose to employ such concepts to other optical laser problems, especially in applications where the delay paths needed for pulse stretching per se are not needed or desired, e.g., more compact and simple optical designs can be created if the purpose is, e.g., for homogenization and not for pulse length extension.
Turning now to
Turning now to
A further embodiment involving, e.g., an isosceles triangle prism 60 is shown schematically in
Since the isosceles prism 60 design redirects the beam 40 through a 90 degree angle it may advantageously be suited for utilization in a position where such a 90 degree turn is already performed by existing optics, e.g., in a laser system, e.g., in a master oscillator power amplifier (“MOPA”) or other possible variations, e.g., a master oscillator power oscillator (“MOPO”) or a power oscillator power oscillator (“POPO”) configuration relay optics arrangement between, e.g., the exit from the MO and the entrance to the PA, whether that be in the same or different laser gas medium chambers. This may be implemented, e.g. in a so-called wave engineering box (“WEB”) currently in use in applicants' assignee's XLA series MOPA configured lasers, such as the turning prism in the MO WEB between the MO chamber and the PA chamber. In this orientation, the prism 60 could be capable of producing alternating inverted images of, e.g., the vertical axis. Also, since the plane of incidence could be in the S plane with respect to the incoming beam 40, the design of the full reflective coatings could be more simple.
Since the prism 60 inverts the beam about the center of the input face, the re-circulating beam will be offset from the input beam by twice the amount that the input beam is offset from the center of the prism 60. The effect of the right triangle prism 50 or isosceles prism 60 can be achieved with the use of individual optical components comprising, e.g., two mirrors and a beam splitter, also providing the means to combine both the homogenizing effects of the dove prism 40 design and the right triangle 50 or isosceles prism 60 design.
The above noted arrangements can be beneficially applied in the field of bandwidth measurement, e.g., utilizing wavemeters such as those described in the above referenced co-pending application Ser. No. 10/293,906, 10/173,190. 10/141,201 referenced above from the latter two of which
Therefore arrangements as discussed above can be useful for reduction of speckle noise and enhancement of the ability to more accurately and consistently track bandwidth and has the advantage of not requiring moving parts such as would be required with, e.g., a spinning diffuser as discussed in more detail below, with the resultant avoidance of a component subject to wear and tear and to possibly producing undesirable effects, such as vibration. Advantageously arrangements as discussed above can by used to alter the coherence cells within the laser beam to reduce its spatial coherence and reduce the speckle noise component, e.g., in the laser output beam and/or in a portion of the beam selected for analysis, e.g., in an etalon spectrometer 190 as shown in
As discussed above, the arrangements of
As shown in
Also as shown in
A second embodiment shown schematically in
Applicants have also discovered during the development a better ways to quickly and effectively and consistently monitor E95 for purposes of on-board wavemeter determinations of that value, e.g., in laser output beams, e.g., in high repetition rate gas discharge laser systems, e.g., utilizing estimations from measurements of FWHM or the like. For a stationary interference pattern induced through diffusion of very narrow band spatially coherent laser light with sufficient coherence length, a so-called speckle pattern adds optical noise to the attempts to measure fringe values. Therefore, e.g., due to illumination with the relatively high-spatial-coherence light from, e.g., an XLA-100 ArF MOPA configured two chamber gas discharge laser manufactured and sold by applicants' assignee, the introduction of repeatable changes in the measured FWHM or E95 of an etalon spectrometer such as 190 shown in
According to an aspect of an embodiment of the present invention standard XLA-100 spectral analysis module (“SAM”) wavemeter being sold by applicants' assignee, containing an enhanced illumination system, e.g., as shown in
It will be understood by those skilled in the art that the diffuser need not spin per se, but simply needs to move relative to the spot of light incident upon it. It could, therefore, with the same effect, be vibrated, translated in one axis or in two axes simultaneously or sequentially, or alternatively schemes could be implemented wherein the spot of light itself is translated relative to a stationary diffuser. the term spinning diffuser as used in this application is intended to cover all of these forms of relative translation of the optically interactive relationship between the spot of light (e.g., an incident beam) and the diffuser.
Spinning the diffuser 110, e.g., a ground glass diffuser, made by a process of sanding the surface of an optical element with sandpaper as is done by applicant's assignee to create, e.g., part No. 103929, which is sold in wavemeters sold by applicants assignee as on-board wavelength and bandwidth metrology units, and which may also be etched, e.g., with ammonium bi-fluoride, as is done by applicants' assignee in creating part NO. 109984 also found in wavemeters sold by applicants' assignee, causes the speckle pattern to move in the far field. By time-averaging the movement of the speckle pattern, the influence of the speckle is reduced to nearly zero. This effect can be verified by scanning the wavelength of the laser (not shown) or the spacing of the etalon 184. At constant input bandwidth, the fringes have a much more constant width as a function of position on the detector 180, when the diffuser is spinning and the speckle pattern is time-averaged. If the motion of the diffuser is stopped, a repeatable pattern of fluctuations in the width of the fringe as a function of position on the detector reappears.
Applicants have therefore proposed an illumination for a spectrometer that makes the spatial dependence of speckle intensity time dependant, e.g., by introducing a time-dependent and/or a position dependent random modulation of the source wavefront via, e.g., the insertion of a spinning (moving) diffuser and/or a source light beam moving with respect to the diffuser. The instantaneous speckle intensity, therefore, is made to have a constant mean by a randomly varying position dependence and, therefore, the time average of the moving speckle pattern can be made spatially homogenous, i.e., a “flat field.” In this manner according to aspects of an embodiment of the present invention the speckle modulation of the time-averaged image formed by this light can thereby be greatly suppressed, reducing, e.g., the uncertainty or error in measurements performed on the image, e.g., measurements impacted by speckle noise, e.g., measurements of the width of a spectrometer fringe to determine the spectral bandwidth with a higher degree of accuracy and repeatability.
At constant input bandwidths according to aspects of an embodiment of t4he present invention applicants have determined that the fringes have a width that, accounting for the dispersive properties of the bandwidth detection instrument being utilized, is constant even though their positions on the detector may be changing. These positions are a function of the wavelength of the illuminating spectrum and the dispersive properties of the instrument. Without a spinning diffuser as defined above, the image of the fringe can be modulated by a stationary speckle pattern, which can introduce an uncertainty r error into the fringe measurements of, e.g., intensity and/or width of the fringe image.
Turning now to
The scans show significant deviations from the expected functions at the enumerated pixel locations, with maxima at around 0.25 pixels. This plot shows the large fluctuation in the FWHM of the etalon fringe as the laser wavelength is tuned across 20 pm. The fluctuations look random at first, but they are very repeatable as evidenced by the overlay of the patterns from the two runs, which are very similar even though they were performed more than 3 hours apart. The scans reflect an 800 pulse average across 4 bursts. This indicates that there can be very significant levels of noise, e.g., where through interpolation the software for current wavemeters of assignee seeks to differentiate fringe widths down to the 1 1/16th of a pixel.
Turning to
Applicants also propose an arrangement according to aspects of an embodiment of the present invention which can provide a measurement value that should more accurately and consistently correlate with the E95 spectral width. The device could be made relatively very compact, e.g., as compared to the wavemeters as shown in
The apparatus according to aspects of an embodiment of the present invention may utilize, e.g., a diffusion section 132 that could, e.g., scramble any spatial-spectral relationships of the laser beam. The next part of the optical system in the path of the beam 40 to the etalon 130 could be a collimator 134 to collimate the diffused beam. The collimation optic 134 can be simple since the optical requirements for a 6 mm diameter, diffraction limited beam are not demanding. The next section following the collimation portion 134 could be the etalon 130 which may be a confocal etalon 130 having a free spectral range (“FSR”) equal to, e.g., the approximate E95 value of the source laser beam 40. as shown in
For the next generation, e.g., XLA-200 series lasers upcoming from applicants' assignee, the FSR could be about 0.5 pm. At this small FSR value the use of a confocal etalon becomes almost a practical necessity. Given a wavelength of 193 nm, e.g., for an ArF gas discharge laser system, e.g., in a MOPA configuration and an FSR of 0.5 pm, the gap distance for an air spaced confocal etalon could be as much as 18.68 mm, i.e., about 0.75 inches. The confocal etalon 130 should have superior geometric finesse over a parallel plate etalon, e.g., 184 as shown in
Immediately following the etalon 130 according to aspects of an embodiment of the present invention could be the detector section 122. Since the etalon 130 will be used with a collimated input, no fringe imaging optics would be required. This eliminates the need for long focal length systems that can be subject to alignment problems and require significant space. All that would be required between the etalon 130 and the detector 122 would be, e.g., an aperture 140 to eliminate stray light. The detector 122 could receive the full output beam of the etalon 130 not just a linear section as in previous etalon spectrometer designs such as shown in
To measure, e.g., the E95 of the input light 40, the etalon 130 or the source 40 will need to be scanned. The etalon 122 can be scanned by physically changing the gap distance between the confocal reflectors 132, 134 or by changing the pressure of the gas medium in between these mirrors 134, 136. according to an aspect of an embodiment of the present invention a more convenient way of scanning can be scan the wavelength of the source 40 or the angle of incidence of the source beam 40, as discussed in more detail below. This would eliminate the necessity for any moving parts in the E95 monitor. After the etalon 130 or source 40 is scanned, a modulation value can be calculated from the output signal of the detector 122, as illustrated in
According to an aspect of an embodiment of the present invention illustrated schematically in
According to aspects of an embodiment of the present invention the acousto-optical modulator 150 could provide the scanning mechanism for the etalon 130, e.g., with a chirp signal provided to the modulator 150 to scan the etalon 130 over the angular range that would cover the FSR of the etalon 130. The acousto-optic modulator 150 could be located as close to the entrance of the etalon 130 as possible to mitigate vignetting by the aperture inside the etalon 130, e.g., 181K as shown in the etalon embodiment of
According to aspects of an embodiment of the present invention to measure the E95 of the input light 40, the etalon 130 can be scanned by the acousto-optical modulator through at least an entire FSR. After the etalon is scanned, the above noted modulation value calculated from the detector signal can be generated. This modulation value should correlate to the magnitude of the E95 of the source. An actual E95 measurement can then be generated as discussed above.
The devices 120 shown in
According to aspects of an embodiment of the present invention the destruction of spatial coherence in the beam, e.g., for use in measuring bandwidth and like metrology, this technique is equally applicable in the measurement of bandwidth with more accurate and also bulkier and more expensive grating spectrometers. For reasons of cost and bulkiness, such grating spectrometers (not shown) are not well adapted for on-board wavemeters of the type discussed above and are more used in the laboratory and in manufacturing, e.g., for quality control metrology and calibration tasks. However, the improvements to on-board spectrometry for laser wavemeters as discussed above according to aspects of embodiments of the present invention are equally applicable to improvement the measurements obtainable from other spectrometry metrology tools, e.g., grating spectrometers.
It will be understood by those skilled in the art that the aspects of the disclosed embodiments of the present invention can be varied from the specific embodiments disclosed. In operation, the beam homogenization apparatus and methods discussed above can be implemented in the laser output pulse beam path, e.g., at the output of the laser, e.g., the output of a PA chamber in a MOPA single or dual chamber configuration as such configurations are known in the art. This could be implemented in a beam delivery unit including, e.g., downstream of any pulse stretcher unit employed, in order to, e.g., even further reduce beam spatial coherency, e.g., to further reduce speckle effects. Moreover, these apparatus and methods may be used in the beam path within metrology tools, e.g., at the output of a MO chamber, the output of a PA chamber and even in any beam delivery unit, e.g., in a beam analysis module at the exit from the beam delivery unit and entrance to a lithography tool. As used herein, therefore, the term beam path includes any portion of the path of the pulses of laser light as such pulses are being generated, e.g., between an oscillator chamber and its associated line narrowing module or within the line narrowing module itself as such line narrowing modules are known in the art, at the exit of a laser chamber, including between, e.g., an MO and PA in a multi-medium laser configuration, including e.g., dual chambered MOPA configurations, and further in any beam delivery unit (“BDU”) in the beam path to the ultimate destination of a UV-light-using tool. Similarly, while prism based beam homogenizers have been disclosed, other forms of optical beam homogenization can be employed as will be understood by those skilled in the art to carry out the purposes and intentions of aspects of embodiments of the present invention, and the term beam homogenizer will be understood to cover the embodiments disclosed and such other homogenizers. Homogenization may be carries out in multiple axes, e.g., horizontal and vertical and may be conducted along with rotational homogenization, as discussed above, and the term beam homogenizer should be interpreted to incorporate these aspects of homogenization as well. The homogenizer can be in the laser system itself upstream of any beam delivery unit or in a beam delivery unit intermediate the laser light source and a light using tool.
It is also well known that so-called wavemeters for the types of equipment with which aspects of embodiments of the present invention are used to measure such things as bandwidth and center wavelength, especially in regard to bandwidth, are subject to measuring errors. Especially this is so for on-board metrology tools, i.e., pulse energy and wavelength and bandwidth detectors where, e.g., the etalon or other dispersive optical element, e.g., a grating, has a so-called slit function that convolves with the source spectrum and must be deconvolved, actually or by some estimations and calculations as is known in the art. However, the resulting determination of, e.g., bandwidth per se is only an estimated bandwidth. Therefore the terms bandwidth and bandwidth measurement and bandwidth detection as used herein should take into account these aspects of, e.g., bandwidth determinations, particularly with on-board wavemeters as are known in the art. Wavemeters can be considered to be limited to on-board wavelength, bandwidth and pulse energy detectors as are known in the art, and not, e.g., more accurate spectrometers, e.g., used in laboratories and in manufacturing, e.g., for calibration purposes. However, as used in the present application wavemeter means all forms of spectral and center wavelength metrology tools wherein beam characteristics, e.g., spatial coherency as discussed above, can impact the accuracy of the metrology tool measurements and ultimate output representative of the estimation of, e.g., bandwidth for which the tool is employed and according to how it operates. These can include, e.g., all types of imaging spectrometers, e.g., grating spectrometers, e.g., ELIAS spectrometers made by LTB and utilized, e.g., for laser initial test in manufacturing, field testing of bandwidth performance and other like laboratory testing. It will also be understood that the term source beam as used in the present application means both the laser output beam itself and any portion thereof, e.g., diverted into an on-board, in-BDU or laboratory/manufacturing metrology tool for analysis. It will be understood also that, as discussed above, the homogenization of the beam is not for purposes of pulse stretching, especially in metrology uses of aspects of embodiments of the present invention. The temporal coherency length is important and the optical delay paths discussed above are at least that but only need to be in that range, and not the much longer delays for pulse stretching as discussed for example in above referenced co-pending applications and the U.S. Pat. No. 6,535,531 patent referenced above, and approximately the dame delay as the temporal coherence length shall have this meaning as used in the present application. It will also be understood as is well known in the art that fully or maximally reflecting surfaces have some absorption occurring therein within the limitations of the reflecting surfaces, especially with optical elements having coatings to tune the reflectivity, e.g., for a range of desired wavelengths, and that the terms fully reflective or reflecting or maximally reflective or reflecting means as fully or maximally reflective as can be achieved with a given selection of material, coating, type of optical element, etc. but not necessarily 100% reflective.
It will also be understood that while pulse stretchers as have been described above and in the above referenced patents and application using imaging mirrors can serve to invert the beam and thus reduce speckle, the specific applications of this phenomenon disclosed in the present application involve optics with are either fully transmissive, e.g., the dove prisms disclosed above, which themselves are partially reflective at the prism interface or prisms which transmit the beam partly, i.e., at lease internally to there be reflected by the totally reflecting side walls, as distinguished from convex mirrors used in pulse stretchers, and the term transmissive, as used in this application is intended to distinguish the homogenizers disclosed in the present application from convex imaging mirrors.
The present application is related to co-pending U.S. application Ser. No. 10/676,175, filed on Sep. 30, 2003, entitled GAS DISCHARGE MOPA LASER SPECTRAL ANALYSIS MODULE, Attorney Docket No. 2002-0092-01, and Ser. No. 10/615,321, filed on Sep. 30, 2003, entitled OPTICAL BANDWIDTH METER FOR LASER LIGHT, Attorney Docket No. 2003-0002-01, and Ser. No. 10/615,321, filed on Jul. 7, 2003, entitled OPTICAL BANDWIDTH METER FOR VERY NARROW BANDWIDTH LASER EMITTED LIGHT, Attorney Docket No. 2003-0004-01, and Ser. No. 10/609,223, filed on Jun. 26, 2003, entitled METHOD AND APPARATUS FOR MEASURING BANDWIDTH OF AN OPTICAL OUTPUT OF A LASER, Attorney Docket No. 2003-0056-01, and Ser. No. 10/739,961 filed on Dec. 17, 2003, entitled GAS DISCHARGE LASER LIGHT SOURCE BEAM DELIVERY UNIT, Attorney Docket No. 2003-0082-01, and Ser. No. 10/676,224, filed on Sep. 30, 2003, entitled OPTICAL MOUNTINGS FOR GAS DISCHARGE MOPA LASER SPECTRAL ANALYSIS MODULE, attorney Docket No. 2003-0088-01, and Ser. No. 10/789,328, filed on Feb. 27, 2004, entitled Improved Bandwidth Estimation, Attorney Docket No. 2003-0107-01, and Ser. No. 10/712,545, filed on Nov. 13, 2003, entitled LONG DELAY AND HIGH TIS PULSE STRETCHER, Attorney Docket No. 2003-0109-01, and Ser. No. 10/712,545, filed on Nov. 13, 2003, entitled LASER OUTPUT LIGHT PULSE STRETCHER, Attorney Docket No. 2003-0121-01, each of which is assigned to the assignee of the present application and the disclosures of each of which are hereby incorporated by reference. The present application is also related to United States Published Patent Application No. 20030161374A1, with inventor Lokai, published on Aug. 28, 2003, entitled HIGH-RESOLUTION CONFOCAL FABRY-PEROT INTERFEROMETER FOR ABSOLUTE SPECTRAL PARAMETER DETECTION OF EXCIMER LASER USED IN LITHOGRAPHY APPLICATIONS, based on an application Ser. No. 10/293,906, filed on Nov. 12, 2002, and United States Published Patent Application No. 20030016363A1, with inventors Sandstrom et al., published on Jan. 23, 2003, entitled GAS DISCHARGE ULTRAVIOLET WAVEMETER WITH ENHANCED ILLUMINATION, based on an application Ser. No. 10/173,190, filed on Jun. 14, 2002, and United States Published Patent Application No. 20020167986A1, with inventors Pan et al. published on Nov. 14, 2002, entitled GAS DISCHARGE ULTRAVIOLET LASER WITH ENCLOSED BEAM PATH WITH ADDED OXIDIZER, based on an application Ser. No. 10/141,201, filed on May 7, 2002 all of which are assigned to the common assignee of the present application, the disclosure of which are hereby incorporated by reference.