1. Field of the Invention
The present invention relates to optical pellicles for preventing adhesion of dust or other particles to a mask used in a microlithographic exposure apparatus.
2. Description of Related Art
Microlithography, which is also referred to as photolithography, is a technology for the fabrication of integrated circuits, liquid crystal displays and other microstructured devices. More particularly, the process of microlithography, in conjunction with the process of etching, is used to pattern features in thin film stacks that have been formed on a substrate, for example a silicon wafer. At each layer of the fabrication, the wafer is first coated with a photoresist or another material that is sensitive to radiation, for example deep ultraviolet (DUV) light. Next, the wafer covered with the photoresist is exposed to projection light through a mask in a projection exposure apparatus. Amplitude masks contain a pattern of opaque structures that block transmission of a correspondingly patterned portion of the incident light. During projection of the mask, an inverse pattern of the mask pattern is imaged on the photoresist, usually at a reduced scale. After exposure, the photoresist is developed to produce an image corresponding to the pattern contained in the mask. Then an etch process transfers the circuit pattern into the thin film stacks on the wafer. Finally, the photoresist is removed. Repetition of this process with different masks results in a multi-layered microstructured component.
Accurate reproduction of the mask pattern on the photoresist is of paramount significance for the production of such microstructured components. Therefore, the integrity of the mask must be protected to allow repeated use. Small particles, such as airborne dust or fibers, are a significant source for degrading the accuracy of mask pattern reproduction. Even very small particles can alter light transmission when positioned near the focal plane of the mask. As a result, these particles can produce defects in the component to be produced.
To protect the integrity of the mask pattern, it is known to use an optical pellicle, which is often simply referred to as pellicle. A pellicle includes a thin membrane having a uniform thickness. Typically, the optical pellicle is supported above the mask surface by a frame. The membrane acts as a dust cover that is capable of keeping particles away from the surface of the mask. Instead, particles are collected on the pellicle surface, but remain at a distance from the mask that is determined by the height of the frame. Thus the particles are positioned relatively distant from the front focal plane (i.e. the mask plane) of the projection lens, and hence the ability of the particles to disturb the imaging of the mask pattern onto the photoresist is significantly mitigated.
Pellicles should not affect the transmitted light as such. This involves, in particular, that pellicles should have a very high transmittance and should not introduce distortions. To achieve a high transmittance, pellicles are generally constructed of a material that absorbs very little light at the light wavelength selected for the microlithographic process. Distortions are avoided by ensuring a very uniform thickness at a specific value between approximately 0.5 μm to 2 μm.
When sources that produce UV light of longer wavelengths are used in the projection exposure apparatus, nitrocellulose or cellulose acetate provides pellicle membranes with high transmittance, but an anti-reflective coating (“AR coating”) is required due to the relatively high refractive index of these materials. For shorter wavelengths in the deep ultraviolet (DUV) spectral range, such as 248 nm, 193 nm or 157 nm, membranes constructed from commercially available fluoropolymer resins have been used successfully. For example, the fluoropolymers CYTOP from Asahi Glass and AF-1600 from DuPont have been found to be suitable. Pellicles constructed with these fluoropolymers have a high transmittance for these wavelengths and have such a low refractive index that an AR coating could be dispensed of.
Nevertheless AR coatings are often applied to the membrane for various reasons. The most important motives are the improvement of the transmittance of the pellicle and the reduction of transmittance sensitivity to membrane thickness variations. Another object in the design of AR coatings may be to prevent transmittance variations as the wavelength changes.
For example, U.S. Pat. No. 5,741,576 A1 describes a pellicle comprising a membrane and an AR coating. The pellicle has a transmittance of at least 99% for a first wavelength range from 361 nm to 369 nm and also for a second wavelength range from 430 nm to 442 nm.
Suitable materials and production methods for applying AR coatings to membranes are disclosed in U.S. Pat. No. 5,674,624.
US 2002/0181092 A1 discloses a pellicle that is electrically conductive so as to achieve an antistatic effect.
Pellicles comprising coated membranes are also described in U.S. Pat. No. 4,657,805, U.S. Pat. No. 5,008,156, U.S. Pat. No. 4,759,990 and EP 0 488 788 A.
One approach to reduce the minimum feature size in microstructured components is based on the concept of introducing an immersion liquid into the interspace between the last lens element of the projection lens on the image side and the photoresist. This enables an increase of the image side numerical aperture (NAi) of the projection lens to values larger than 1.
However, it has been discovered that using conventional pellicles in projection exposure apparatuses having an image side numerical aperture beyond 1 results in a degradation of the image quality.
It is therefore an object of the present invention to provide a pellicle that is particularly suited for being used in a projection exposure apparatuses having an image side numerical aperture in excess of 1.
According to a first aspect of the invention, this object is achieved by a pellicle for use in a microlithographic exposure apparatus that has, for an operating wavelength of the microlithographic exposure apparatus, a transmittance maximum for light rays that impinge on the pellicle with angles of incidence between 2° and 25°.
The transmittance maximum may be local or global. The term “local transmittance maximum” refers to a maximum of the transmittance in the presence of a further maximum with a still larger transmittance inside or outside the specified range of angles. This situation may occur, for example, if a still larger transmittance is achieved for perpendicular incidence or at an angle of incidence larger than 25°.
The term “global” refers to the situation in which there is no other transmittance maximum at all, or in which there is a further maximum inside or outside the specified range of angles, but at this further maximum the transmittance is nevertheless smaller as compared with the global maximum.
This new approach deviates from the conventional design rule that assumes perpendicular incidence when attempting to achieve a transmittance maximum. According to this first aspect of the invention, the transmittance maximum usually obtained at perpendicular incidence is deliberately shifted towards oblique incidence. This is because projection lenses having a high image side numerical aperture NAi also have a large object side numerical aperture NAo which is given by NAo=M·NAi, where M is the magnification of the projection lens.
For example, if NAi=1.4 and the magnification of the projection lens is M=¼, the object side numerical aperture is NAo=0.35. This corresponds to a maximum angle of about 20°. For comparison, a conventional projection lens that is not designed for immersion operation may have an image side numerical aperture of 0.8, with maximum angles at the object side of the projection lens of only 11.5°.
This considerable increase of the maximum angles occurring at the object side of the projection lens in immersion systems has the consequence that the light rays traversing the pellicle have larger angles of incidence as well. In conventional pellicles the transmittance maximum is achieved at perpendicular incidence, and the transmittance does not considerably decrease for angles of incidence up to about 12°. However, at larger angles of incidence the transmittance of the pellicle significantly drops to values below 98%. For an angle of incidence of 20°, for example, the transmittance may be as low as 90%. This dependence of the intensity on the angle of incidence contributes to the image degradations that have been observed in immersion projection lenses when being used with conventional pellicles.
According to the first aspect of the invention, however, the design objective of the pellicle is altered such that a local or global transmittance maximum is achieved at angles of incidence between 2° and 25°. As a result, the sharp drop of the transmittance is, so to say, shifted towards larger angles of incidence beyond the range of angles that actually occur at the object side of the projection lens. This, of course, also means that the transmittance for perpendicular incidence is reduced if compared with conventional pellicles. However, a good reproduction of the pattern contained in a mask on the wafer does not require maximum transmittance at a certain angle, but both a high mean transmittance on the one hand and a high minimum transmittance on the other. To be more specific, the pellicle should be designed such that the mean transmittance, for a given range of angles of incidence that is determined by the projection lens, is greater than 95% and preferably greater than 98%. The variations of the transmittance over this range should be, on the other hand, less than 5% and preferably less than 2.5%.
The range of angles of incidence is between 0° and arcsin(NAo) with NAo being the object side numerical aperture of the projection lens. In practice this may result in a range of angles of incidence between 0° and about 25° for projection lenses with a very high object side numerical aperture NAo. For smaller values of NAo, the range of angles of incidence may be smaller, for example between 0° and 15°. For particular illumination settings, there may be a non-continuous range of angles of incidence, for example between arcsin(NAo/2) and arcsin(NAo).
Computations and experiments have shown that a high mean transmittance and small transmittance variations may be achieved if the transmittance maximum is achieved for angles of incidence between 5° and 20° and preferably between 10° and 15°.
For achieving such an optical behavior the pellicle may be formed by a single membrane that is not covered by an anti-reflection coating. If the membrane is not covered by an anti-reflection coating so that it is in immediate contact with the surrounding gas, the optical properties of the pellicle, and in particular the dependence of the transmittance on the angle of incidence is solely determined by the refractive index of the membrane and its thickness. Using an uncoated membrane as a pellicle may be advantageous for cost reasons.
Certain optical properties of the pellicle may be improved if the pellicle comprises not only a membrane but also an anti-reflective coating applied to the membrane. Such a coating may comprise at least two layers and be applied to one or both sides of the membrane. The optical effect of the anti-reflective coating may be selectively determined in view of various optical properties. For example, the anti-reflective coating may be designed such that the transmittance maximum of the pellicle for light rays that obliquely impinge on the pellicle is achieved for different operating wavelengths. An antistatic effect, as is known in the art as such, may also be achieved. Furthermore, the outmost layer of the coating may be designed such that the adhesion of dust or other particles is reduced. This property may be achieved if the outmost layer contains an organic component.
In another advantageous embodiment the pellicle is designed such that its transmittance does not, as is the case in prior art pellicles, decrease, but continuously increases with increasing angles of incidence. Such a dependence may be advantageous, for example, if the projection exposure apparatus contains optical elements in a pupil plane that have a lower transmittance with growing distance from the optical axis, for example a thick biconcave lens. The pellicle may then be used for achieving a compensation of such generally undesired dependencies. If the projection lens is designed for immersion operation, the transmittance may increase with increasing angles of incidence in such a way that an absorption of oblique rays in the immersion liquid is substantially compensated for. Since the immersion liquid is in immediate vicinity to the back focal plane of the projection lens, angles of incidence at the pellicle directly translate into angles of incidence on the photoresist. Since the transmittance of known immersion liquids cannot be neglected, oblique rays travelling a longer distance in the immersion liquid suffer a stronger absorption than perpendicular rays. This effect can be compensated for by an opposite dependence of the transmittance in the pellicle.
If a still more homogenous angular intensity distribution is required, it may be considered to arrange an additional absorptive filter element in or in close proximity of a pupil plane of the projection lens. The filter element has a locally varying transmittance that may be determined such that the dependency of the transmittance of the pellicle on the angle of incidence is at least substantially compensated for. In the presence of an immersion liquid, the locally varying transmittance of the filter element may be determined such that both the dependency of the transmittance of the pellicle on the angle of incidence and also the dependency of the transmittance of the immersion liquid on a second angle of incidence with respect to the light sensitive layer are (at least substantially) commonly compensated for. Instead of or in addition to arranging such an absorptive filter element in or in close proximity of a pupil plane, an absorptive filter element with an angularly varying transmittance may be arranged in or in close proximity to a field plane, for example the mask plane, the wafer plane or an intermediate image plane.
According to a second aspect of the invention, the above stated object is achieved by a pellicle comprising a membrane and an anti-reflective coating applied to the membrane. The membrane and the anti-reflective coating are designed such that, for an operating wavelength of the microlithographic exposure apparatus, the transmittance of the pellicle varies by less than 2% for angles of incidence between 0° and 15°, more preferably between 0° and 25°. Even more preferably the transmittance varies by less than 1% in these angular ranges. This aspect of the invention is based on the discovery that it is possible, with a suitable design of anti-reflective coatings, to achieve a transmittance that is, for a large range of angles up to 15°, almost constant. The transmittance maximum may be as high as 98% or even 99.5%.
Consequently, there is no need for an additional absorptive filter in a pupil plane that may compensate for the dependency of the transmittance of the pellicle on the angle of incidence.
Having a transmittance that is almost independent of the angle of incidence over the required range of angles is often the favorable solution in view of imaging properties. However, the application of a plurality of thin layers on one or preferably on both sides of the membrane may involve a complicated and costly manufacturing process. Since pellicles have a restricted life time due to material degradations, costly pellicles may considerably increase the overall running costs of the projection exposure apparatus.
Various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings in which:
The projection exposure apparatus 10 further includes a projection lens 20 containing a multiplicity of lens elements. For the sake of simplicity, only very few lens elements L1 to L5 are schematically indicated in
An interspace formed between the photoresist 26 and the last lens element L5 of the projection lens 20 is filled with an immersion liquid 32. The refractive index of the immersion liquid 32, which may be water or an oil, for example, is preferably chosen such that it approximately coincides with the refractive index of the photoresist 26. Immersion operation makes it possible to design the projection lens 20 with an object side numerical aperture NAo>1. In the embodiment shown in
The mask 22 is protected against dust and other particles by a pellicle 34 that is supported by a frame 36 above the patterned mask surface.
Adhesives 44 are used for attaching the pellicle 34 to the frame 36 and also to attach the frame 36 to the underside 40 of the mask substrate 38. The patterned chrome layer 42 is therefore received in a cavity that does not that no such particles may adhere to the patterned chrome layer 42 and be imaged onto the photoresist 26.
Although the projection exposure apparatus 10 is usually installed in a clean room, there may nevertheless be particles 48 having a significant size in the surrounding atmosphere. If such particles 48 adhere to the underside of pellicle 34, they are considerably outside the object plane 24 of the projection lens 20. As a result, such particles 48 are not imaged onto the photoresist 26. Although the particles 48 may block a portion of the projection light that has passed the patterned chrome layer 42, this will not have a noticeable adverse effect on the image quality.
In the embodiment shown in
The transmittance maximum Tmax=99.9% is obtained for an angle of incidence of about 12.2°, i.e. for light rays that obliquely impinge on the pellicle 34. This is not an advantageous effect as such, but it ensures that the variations of the transmittance T are, for all possible angles of incidence α, very small, namely less than about 2%. In most cases such variations of the transmittance T for different angles of incidence can be tolerated and do not significantly deteriorate the image quality.
Even smaller variations of the transmittance T may be possible if the mean transmittance Tm is reduced. In
The transmittance properties of the pellicles described above may also be obtained with different material and thicknesses specifications. With the support of commercially available software it is possible to determine various other specifications that achieve a similar result. The choice for a particular design may then also be influenced by considerations relating to the manufacturing process.
This will now be explained with reference to
The last lens L5 of the projection lens 20 is immersed in the immersion liquid 32 covering the photoresist 26. From
Generally, however, it will be difficult to achieve a complete compensation in a strict sense. If a significant residual angular dependency of the attenuation remains, it may be considered to introduce a gray filter 82 in a pupil plane 84 of the projection lens 20, as is shown in
A gray filter may also be advantageous if the projection lens 20 is not designed for immersion operation, or the immersion liquid 32 has such a small absorption that it does not introduce a significant angular dependence of the attenuation. In such a case the filter 82 may be designed such that transmittance variations of the pellicle, as are shown in the graph of
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP06/05833 | 6/19/2006 | WO | 00 | 5/12/2008 |
Number | Date | Country | |
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60700142 | Jul 2005 | US |