CA1252228A - Deep-uv lithography - Google Patents

Abstract

Abstract:
The present invention relates to an apparatus and method for optical lithography. The apparatus is comprised of stationary equipment including a laser source and equipment including a stepping table physically separated from the stationary equipment. A unit is provided for directing signals from the laser source in the stationary equipment to the second mentioned equipment to maintain a prescribed alignment between the direction of propagation of the signals and the second-mentioned equipment even during movement of the second-mentioned equipment due to stepping of the table.

Description

2~3 DEEP-W LITHO~RAPHY

This is a division of copending Canadian Patent Application serial number 484,~58 which was ~iled on June 20, 1985.
Backgr_und__f_ he_ I_v _ti__ This invention relates to optical lithography and, more particularly, to apparatus and methods for achieving short-wavelength optical lithography adapted for ~abricating high-quality fine-line semiconductor devices.
It is known that the resolution limit (Lmin) for equal lines and spaces in an optical imaging system can be expressed as L i ~ K~/NA (1) where R is a constant whose value is typically between 0.
and 1.0 deperlding on processing and illumination conditions and resist characteristics, ~ is the wavelength of the exposing radiation and ~A is the numerical aperture of the projection optics.
It is apparent Erom (1) that the minimum printable feature can be reduced by decreasing ~ or by increasing NA. But, since the depth of focus of the system varies inversely as tNA)2, it is usually preferable in a practical high-resolution system to achieve the desired Lmin by reducing ~ rather than ;ncreasing ~A.
The present invention is directed to a novel short-wavelength lithograph system.
Summary of the Invention ______ _________________ In accordance with an aspect of the invention there is provided apparatus for optical lithography, comprising stationary equipment including a laser source, equipment including a stepping table physically separated from said stationary equipment, and means for directing signals from said laser source in said stationary equipment to said second-mentioned equipment to maintain a prescribed alignment between the direction of propagation of said ~d~

;2ZZ~

signals and said second-mentioned equipment even during movement of said second-mentioned eq~i~ment due to stepping of said table.
In accordance with another aspect of the invention there is provided a method of maintaining the output beam of a laser aligned relative to movable equipment at which the beam is directed, said method comprising the steps of directing said beam at a photodetector array mounted on said movable equipment, said array being adapted to generate electrical signals representative of variations of said beam relative to a prescribed alignment with respect to said array, and applying said electrical signals via a feedback loop to a deflection assembly that maintains said beam aligned with respect to said array.
~ lithograph system according to the invention incl~de~ a narrow-bandwidth tunable laser operating at a wavelength in tlle deep- W range. A monochromatic all-fused-silica lens assembly is utilized to direct the output of the laser to successive portions of the surface of a resist-coated wafer mounted on a movable support, e.g., a known "stepping table".
The combination of a narrow-bandwidth laser and a monochromatic lens assembly in accordance with the invention makes it possible to quickly and easily accomplish focus tracking in the system. This is done by directing the output of a laser onto the surface of a workpiece via a projection lens and controlling the wavelength of the laser to maintain the focal length of the lens equal to the lens-to-workpiece surface spacing.
Brief Descri_tion of the Drawin~
_ __________ __________________ The present invention taken in conjunction with the invention disclosed in copending Canadian Patent ~pplication serial number 48~,658, which was filed on June 20, 1985 will be described in detail hereinbelow with the ~5;22'~8 aid of the accompanying drawings, in which:
FIGS. 1 and 2 taken together schematically depict an apparatus in accordance with the invention for achieving short-wavelength optical lithography; and FIG. 3 shows in more detail a particular implementation of a portion of FIG. 1.
Detailed Description _______ _______ ___ The invention is described in connection ~Jith a known type of "step-and-repeat" lithographic system.
In accordance with one feature of the invention, a laser illumination source is physically separated from the movable table portion of the system. Thus, for example, the equipment 10 including laser 12 shown in FIG.
1 is advantageously located at a site removed from the equipment 1~ including stepping table 16 shown in FIG. 2.
In this arrangement, the laser heam provided by the equipment 10 i~c~ propagated through air or controlled space to the equipment 14, as inciated by arrow 18 in FIG. 1.
(Actually, as will be clear later below, two coaxially disposed laser beams are transmitted from the equipment 10 in the direction of the arrow 18. One beam constitutes the exposing radiation. The other beam is utilized only for alignment control purposes.) There are several reasons for physically separating the aforementioned equipments 10 and 14. In some cases, for example, the laser 12 shown in FIG. 1 includes a toxic constituent which ~or safety considerations should he located at a site remote from operating personnel.
In operation, the stepping table moves successive portions of a resist coated semiconductor wafer 40 into the 2~1 path of the illuminating radiation. In the past~ after each indexing of the table, a delay was necessary to allow damping out of vibrations caused by the table movements before the illuminating beam was turned on. This is time consuming.
In accordance with a feature of the invention, instrumentalities are provided in the equipments 10 and 14 for instantaneously moving the laser beams in conformity with the vibrations in the table 16 for maintaining the l~ser beams t8 aligned relative to the table. Thus, after each indexing of the table, the beam can be more quickly turned on. Illustratively, these instrumentalities include standard driven galvanometer mirrors 20 and 22 in the equipment 10 and a conventional quadrant photodetector or position-sensitive photodetector 24 mounted on the table 16. Electrical signals provided by the array 24 are applied to differential amplifiers 26 and 28 in feedback loops that respectively control galvanometer motors 30 and 32. The motor 30 is mechanically coupled to the mirror 20 via a Y-axis parallel shaft 34, and the motor 32 is coupled to the mirror 22 via a Z-axis-parallel shaft 36. By selective rotation of the mirrors 20 and 22, the orientation of the laser beams 18 emanating from the equipment 10 is varied in a controlled manner to compensate for vibratory movement of the table 16.
Under quiescent conditions, the desired orientation of the laser beans 18 relative to the table 16 is established by steady-state signals applied to the galvanometer motors 30 and 32 from a control computer 38. The additional variable signals supplied by the differential amplifiers 26 and 28 to the motors 30 and 32 are superimposed on the steady-state signals supplied by the computer. This proces~s is clescribed furtl1er hereinafter.
Each of the lenses includeci in the equipment 14 of llG. 2 is made only of fused silica. ~`used silica is a highly sta~le material that is highly transr?arer1t to sl!ort-~25;2~

wavelength light. Moreover, fused silica can be ~abricated with good precision to form specified lens designsO
Despite these apparent advantages, applicant is the first to have proposed the use of a single optical material S (fused silica) to make a high-quality lens assembly for short-wavelength (for example, deep-U~) optical lithography based on laser illumination. Hereto~ore, it has been customary to fabricate lenses utilizing multiple materials to correct for chromatic aberrations.
Once he designed an all-fused-silica lens assembly, applicant recognized that a laser source to be combined with the assembly must as a practical matter have an extremely narrow bandwidth if chromatic ~berrations in the single-optical-m~terial assembly were to be avoided~
Since chromatic aberrations are unavoidable with a sinyle-optical-material design, if the laser source bandwidth is not suitably narrow, the projected image on the laser-beam-illuminated wafer 40 (FIG. 2) would be unacceptably blurred.
But applican~ found that all suitable short-wavelength laser sources of adequate power were pulsed lasers that inherently exhibit excessively broad ~andwidths. At that point, the obvious thing to have done, as other workers in the art have, would have been to redesign the lens assembly to be free of chromatic aberrations with the available source bandwidths. But this would have entailed employing optical materials other than only fused silica. Instead, applicant embarked on the unobvious course of retaining an all-fused-silica lens design and redesigning the laser source to exhibit an appropriately narrow bandwidth. This unique approach allows the realization of a superior len.s aesi(3n and, moreover, is t"e basis for achievin~ electronic focus tracking as well as for achieving electronic tuning of the laser source. Such tuning allows the source to be matched to the operating characteristics o~ the lens assembly, as will be speciLIed in detail later below.

~L~S;22~

Illustratively, the laser 12 included în the equipment 10 of FIG. 1 comprises an excimer laser. This category of lasers is capable of W emission at wavelengths from, for example, below 4000 R to below 2000 A.
Excimer lasers and their applicatiOn to lithography are described in a number of publications.
These include: "Laser Projection Printing" by G. M. Dubroeucq et al, Proceedings of Microcircuit Engineerin~ Conference, Aachen, Germany, September 1979, pages 328-33-/; "Applications of Excimer Lasers in Microelectronics" by T. McGrath, Solid State Techno ~ , Deccmber 1983, pages 165-169; "Deep UV Exposure of Ag2Se/GeSe2 Utilizing an Excimer Laser" by K~ ~. Polasko et al, IEEE Electron Device Letters, Vol. EDL-5, ~o. 1, January 1984, pages 24-26; and "Excimer Laser Projection Lithography" by K. Jain et al, Applied Optics, Vol. 23, No. 5, March 1, 1984, pages 648-650.
By way of example, the laser 12 of FIG. 1 comprises a pulsed KrF gas excimer laser designed to operate at a nominal center wavelength of 2484 ~O
(The fluorine constituent in KrF is highly toxic.) Illustratively, the pulse repetition rate of the laser 12 is selected to be approximately 1000 pulses per second.
Inherently, the KrF excimer laser 12 (FIG. 1) has a spectral bandwidth at the half-power point of approximately l0 ~. But, recognizing that an all-fused-silica lens assembly for hi~h-resolution lithography requires a source bandwidth of less than about 0.1 ~ to be free of chromatic aberrations, applicant combined a bandwidth-narrowing assembly with the laser 12 to achieve an output at 2484 ~~
characteri~.ed by a half-power-point bandwidth of only approximately 0.05 ~. At a repetition rate o~ 1~00 pulses per second, the power oE each such pulse is about 5 millijoules, which characteristics provide an adequate basis ~or uniform high-resolution hiqh-throughput 3LZS2'~

lithography.
Various techniques are avai:Lable for narrowing the inherent bandwidth of the laser 12 One suitable assembly for doing this is shown in FIG. 3 (the figure also showing portions 42 and 44 of the laser). Beam 46 emanating from the laser propagates through a standard low-finesse etalon 48 and impinges upon a conventional grazinq-incidence grating 50 which is spaced apart from a facing high-reflectivity mirror 52. Illustratively, the grating 50 has 3000-to-4000 grooves per millimeter. The elements 48, 50 and 52 constitute both a tuning and a bandwidth narrowing assembly. This assembly is shown in FIG. 1 and identified therein by reference numeral 54 ("bandwidth narrowing" is al50 reEerred to in tt~e art as "line-narrowing").
Thle desired narrow-bandwidth output emanates from assembly 54 and propagates in the direction indicated by arrow 55 in FIG. 3. The arrow 55 is also shown in FIG. 1 wherein it is oriented parallel to the X axis.
The assembly 54 also provides a means for establishing the center wavelength of the laser output 55 at a predetermined value and thereafter precisely maintaining the wavelength at that value (or purposely moving the wavelength off that value to accomplish electronic focus trac~ing). This is accomplished by rotating any one or combination of the elements 48, 50 and 52 about an axis perpendicular to the plane of the paper on which FIG. 3 is drawn. Yor coarse tuning, rotating the mirror 52 and/or the grating 50 is satisfactory. For fine tuning, rotating only the etalon 48 is effective. In practice, it is usually advantaqeous to initially establish the predetermined center wavelength by rotating one or both oE the elements 50 and 52. Thereafter, the laser can be maintained at that wavelength or Eine-tuned therefroln by selectively controlling the orientation of only the etalon 48.
As schematically indicated in FIG. 3, a .. ,, ., ,., ,. ", ,, .~ .

~52~2~3 micropositioner 56 is connected via a mechanical coupler 58 to the etalon 48. In response to signals applied to the micropositioner 56 on line 60; the orientation of the etalon is thereby controlled to maintain the wavelength of the laser beam 55 at a 2redetermined value or to move the wavelength off that value by a specified amount to accomplish electronic focus tracking. The manner in which the micropositioner 56 is so controlled will be described in detail later below.
Various instrumentalities are ~nown in the art for tuning and line-narrowing the output of a short-wavelength laser as is done by assembly 54. In this connection, see, for example: "Injection-Locked, Narrow-Band KrF Discharge Laser Using an Unstable Resonator Cavity" by J. Goldhar et al, ~tlcs Letters, Vol. 1 t No. 6, December 197J, pp. 199-201; "Operating and Beam Characteristics, Including Spectral Narrowing, of a TEA
Rare-Gas Hal:ide Excimer Laser" by T~ J. McKee et al, IEEE
Journal of Quantum Electronics, Vol. QE-15, No. 5, May 1979, pp. 332-334; "Grazin~ Angle Tuner for CW Lasers"
by K. R. German, APplied Optics, Vol. 20, No. 18, September 15, 1981, pp. 3168-3171; and "A Simple Tunable KrF Laser System with Narrow Bandwidth and Diffraction-Limited Divergence" by R. G. Caro et al, Journal Physics D:
Applied Physics, 15, 1982, pp~ 767-773.
The aforedescribed feedback loops for controlling the galvanometer motors 30 and 32 (FIG. 1) require continuous electrical input signals. But the pulsed laser 12 is not capable of providing such signals via the detector 24 tFIG. 2). Hence, a continuous-wave (CW) laser 62 (for example, a standard helium-neon laser operating at 6328 R) is also included in the ~equipment 10. The laser 62 is desi,3ned to provide a continuous reference beam that is coaxial with the a~orespeci~ied beam at 2484 A. In turn, the beam at 6328 A is converted by the detector 24 into continuolls electrical siqnals that are ap~lied to the ~s~

feedback loops that respectively control the galvanometer motors 30 and 32.
Whenever the detector 24 senses that the reference beam at 6328 R is off-center relative to its prescribed alignment with the det,ector 24, correction signals are applied to the motor 30 and/or to the motor 32 to re-establish the prescribed alignment. And, since the beams at 6328 ~ and 2484 ~ are propagated coaxially in the equipment 10, these correction signals are effective to re-estabiish the prescribed alig~ment of the exposing beam at 2484 ~.
The output of the CW laser 62 (FIG. 1) is directed via a high-reflectivit~ mirror 64 to a dichroic mirror 66. ~he mirror 66 is designed to reflect the incident beam at 63~8 R to the right along an X-direction path indicated by arrow 68. The mirror 66 is also designed to transmit most of the incident beam at 2484 ~ emanating from the assembly 54 along the same X-direction path. Thus, the arrow 68 indicates the path along which the Cw beam at 6328 ~ and the pulsed beam at 2484 ~ propagate coaxially to successively impinge upon the galvanometer mirrors 20 and 22. After reflection from the mirrors 20 and 22, the coaxial beams are propagated from the equipment 10. These coaxial beams constitute the previously specified beams 18.
A small portion (for example, about one percent) of the beam at 2484 A emanating from the assembly 54 of FIG. 1 is reflected upward by the mirror 66 along a Y-direction path indicated by arrow 69 to a wavemeter 70. In response thereto, the wavemeter 70 provides an electrical signal to one input of a differential amplifier 72. The other input to the amplifier 72 is ~supplied by the control computer 38. In 3S that way, the output of the amplifier 72 applied to the lead 60 is effective to maintain the output of the assembly 54 at a predetermined center wavelenath specified ~5~2~3 by the computer 38. Or, as will be described in more detail later below, the signal applied to the amplifier 72 by the computer 38 can also be utilized to purposely change the center wavelength to achieve electronic focus tracking.
Further, the aforespecified ability of the computer 38 (FI~. 1) to easily control or adjust the center wavelength of the beam emanating from the assembly 54 simplifies the overall design and fabrication of the e~uipment described herein. This is so because in practice one can rarely make an all-fused-silica lens assembly precisely to a specified prescription. Normally, one would have to install the ~abricated lens assembly in the equipment, test the assembly at a prespecified c:enter frequenc~, and then ~ake the assembly apart to make adjustments therein by further machining, polishing, etc~
Subsequently, re-installation of the lens assembly and further testing in the equipment would be done, and so forth in an interactive fashion until a near-optimal match between the lens assembly and the centerwavelength was obtained. Such mechanical tuning or match-ing of the lens assembly to a fixed prespecified center wavelength is obviously time-consuming and expensive.
By contrast, .in applicant's unique design, it is often possible, after initially installing the all-fused-silica lens asseMbly in the herein-described equipment, to achieve a near-ideal adjustment of the equipment withol~t removing the lens assembly. This is done by leaving the installed assembly intact and adjusting the center wavelength of the exposinq beam, under control of the computer 38, to obtain a near-optimal match between the operating characteristics of the lens assembly as initially fabricated and the operatinq wavelength of the equipment.
.Such electronic, rather than mechanical, adjustment of the equipment is manifestly advantageous.
The laser beams at 2484 A an(i ~32~ A

~5~8 that emanate from the equipment 10 in the direction of arrow 18 are directed at the equipment: 14 shown in FIG. 2.
In particular, these beams are directed at a mirror 74 in the equipment 14. The mirror 74 is designed to be highly reflective at 6328 A and highly transmissive at 2484 A. As a result, most of the 6328 A
-beam is directed to the right in the clirection of arro-~ 76 and most of the 2484 R beam is directed downward in the direction of arrow 78.
The 6328 A beam propagated in the direction of the arrow 76 in FIG. 2 passes through a filter 80. The filter 80 is designed to pass the 6328 ~ bea~ but to block any portion of the 2484 R beam that was reflected by the mirror 74 in the direction o~ the arrow 76. Accordingly, only the CW
beam at 6328 ~ impinges upon the detector 24. In turn, as described earlier above, the detector 24 provides continuous electrical signals in the feedback loops shown in FIG. 1 to control the operation of the galvanometer motors 30 and 32. In that way, the orientation of the 6328 ~ beam 76 relative to the table 16, and thus also the orientation of the coaxially disposed 2484 exposing beam 78, are maintained fixed even durinq vibratory motion of the table 14.
The 2484 A beam propagated downward in FIG. 2 in the direction of the arrow 78 is directed at an adjustable field stop or aperture 82. Illustratively, the diameter of the beam at the stop 82 is designed to be larger than the diameter of the opening in the stop.
In practice, the equal-intensity contour lines of the 2484 R beam transmitted through the stop 82 of FIG. 2 are not svmmetrically disposed with respect to the opening in the stop. Moreover, this asymmetry tends to vary from pulse to pulse. If not compensated ~or~ these factors can result in unsatisfactory illumination uniformity and consequent poor linewidth control at the surface o~ the wafer 40.

~Z5~

In accordance with a featur~e of the invention, the slightly oversize beam directed at the stop 82 is dithered or moved systematically by small amounts AX and ~Z. For an e~posure that cornprises, for example, several hundred successive laser pulses, such movement is effective to accomplish area avera~ing of the pulses transmitted through the stop 82. In turn, this results in better illumination uniformity at the surface of the wafer 40.
Movement of the 2484 ~ beam 78 directed at the stop ~2 (YIG. 2~ to carry out area averaging is controlled by the computer 38 (FIG. 1). Signals applied by the computer 38 via leads 8O and 87 to the galvanometer motors 30 and 32, respectively, are e~fective to implement the aforementioned AZ and ~X movements of the beam across the aperture in the stop 82.
The 2484 A beam 78 that passes through the stop 82 impinges upon a mirror 88 shown in FIG. 2.
This n~irror is designed to reflect a relatively small amount (for example about one percent) of the incident beam. In turn, the reflected portion is directed through a filter 90 to a photodiode 92. The filter 90 is designed to pass light at 2484 ~ but to block li~ht at 6328 ~. In that way, any 6328 A component in the bea~ transmitted by the stop 82 is prevented from impinging on the photodiode 92.
The photodiode 92 of FIG. 2 constitutes part of a dose control and laser trigger arrangement. The photodiode 92 samples a portion of each 24~4 2 pulse and, in response thereto, generates an electrical signal that is applied to a light integrator 94 (FIG. 1).
The control computer 38 s~pplies a second input signal (a dose control signal) to the light integrator 94. In turn, the output of the integrator 94 is applied to the laser 12 as a trigger signal there~or The operation o~ the dose control and laser trigger arrangement is as ~ollows. Under computer control, ~;Z5~

the stepping table 16 is moved by a micropositioner 95 to bring a chip site on the resist-coated wafer 40 into position for exposure to the pattern contained on the reticle 84. (Illustratively, the reticle is assumed to contain a single chip pattern thereon.) The computer 38 then activates the integrator ~4 to tricger the laser 12 to start emitting pulses at 2484 ~. A portion of each pulse is sampled by the photodiode 92 and a signal representative~ thereof is applied to the integrator 94.
When the integrator 94 detects that the prescribed dose set by the computer 38 has been attained, the laser 12 is signaled to cease emitting pulses. Subse~uently, the table 16 is moved to position ~nother chip site on the wafer 40 in po~sition for the next exposure.
Exposure is accom~lished by projection of illumination through a condenser lens 110, through a reticle 84 containing the pattern to be imaged on the wafer 40, and through a projection lens 108. The provision of a virtual source o illurnination for the lens 110 is now described.
As indicated in FIG. 2, the 2484 ~ beam 78 that is transmitted through the mirror 88 is directed toward a collimating lens 96. The lens 96 serves to focus the beam to a small spot and to direct it at a mirror or prism element 98. The small spot comprises a first virtual source of illumination. ~he element 98 is designed to deflect the beam into the edge of the field of a scanning lens assembly 101 represented here by field lens 100 and additional lens elements 102 and 104. In turn, the beam is reflected by a scanning mirror assembly 106 back into the scanninq lens assembly 101.
To achieve ade~1uate illumination of the entrar1ce pupil of the projection lens 108 and hence pro~er ima~ing characteristics on the wafer 40, it is advanta~eous to illuminate about 50-to-75 percel1t of the diameter of the entrance pupil of the lens 108. IllustL-atively, the er1trance pu~il of the lens 108, as defined by drl apeL-tllre ~%5;;~Z8 stop 109 (shown schematically in FIG. 2), is approximately tO0 millimeters in diameter. It is apparent, therefore, that simply relaying the small first virtual source to the lens 108 will not in practice provide adequate illumination of the entrance pupil of the lens 108.
In accordance with one aspect of the invention, the effective size of the virtual source that is actually relayed to the projection lens 108 is substantially increased in size over that of the first virtual source produced by the lens 96. This is done by means of the scanning lens assernbly 101 and the scanning mirror assembly 106. By means of these assemblies, the operation of which is described hereinafter, both the si~e and shape oE the effective virtual source can be selectively varl~d under control of signals ap~lied to the assembly 106 from the computer 38. Significantly, in the co~Jrse of making such variations, no laser light at 2484 g is wasted in the depicted equipment. Hence, all available exposing light is delivered to the surface of the wafer 40 even as changes are made in the size and shape of the illumination relayed to the entrance pupil of the projection lens 108.
The ability to change both the size and shape of the illuminated portion of the entrance pupil of the projection lens 108 can be significant in that it allows, for example, tailoring the illumination to optimize resolution of certain critical features on the wafer 40 and to take maximum advantage of any nonlinearities in the characteristics of the resist layer on the wafer 40.
The scanning mirror assembly 106 schematically depicted in FIG. 2 comprises a mirror 112 and two independently rotatable shafts 114 and 116. The shaft 114 - is oriented parallel to the X axis, whereas the shaft 116 is oriented perpendicular to the X axis. Rotation back and forth of the shaft 116 causes the mirror 112 to rock back and forth, as indicated by double-headed arrow 118. At the same time that rocking occurs, the shaft 114 is turning, as indicated ~y arrow 120. In other words, as the mirror 1;~5;~228 rocks in response to rotation of the shaft 116, the rocking mirror is independently rotated by the shaft 114. As a consequence, a relatively large area A in a Y-Z plane immediately to the left of the lens 100 can be substantially filled with the successive pulses supplied by the laser 12 of FIG. 1 to form a large-area virtual source.
Illustratively, several hundred successive pulses are supplied by the laser 12 during each interval in which a chip site on the wafer 40 is being exposed.
The size of the aforespecified large-area virtual source can be changed by varying the extent to which the mirror 112 is rocked by the shaft 116. Additionally, the shape of the virtual source can be changed by varyin~ the speed o~ rot~tion of the shat 11~ while the mirror 112 is being rocked Liclht emanating from the relatively large-area virtual source formed to the left of the lens 100 (~IG. 2) is directed by the relay lens 110 to illuminate the pattern contained on the reticle 84. In turn, light propagated through the reticle 84 is imaged by the lens 109 onto a chip site on the surface of the wafer 40. Illustratively, the lens 109 forms a reduced (for example 5-to-1 reduced) version of the reticle pattern on the wafer surface.
In a standard exposure system, conventional focus tracking is accomplished by mechanically changing the projection lens-to-wafer distance. Typically, this is done either by moving the optical column of the system or by moving the wafer. In either case, the adjustment is time-consuming and, moreover~ may cause undesirable mechanica~
3n resonances in the system.
In accordance with one aspect of the present invention, focus tracking is carried out quickly in a nonmechanical manner. The ability to do so stems from the use of lenses made from a single optical material. Such lenses, unlike those corrected for chromatic aberrations, exhibit an appro~imately linear relationship between wavelenatl1 and tocal distance. I~ence, by electronically changing the wavelength of the laser 12 (FIG. 1), the focal plane of the projection lens tO8 (FIG. 2) is also changed.
The operation of the focus tracking arrangement is as follows. First, a standard foc~ls sensor 111 detects S whether or not the distance between the projection lens 108 and the surface of the wafer 40 has changed from a prespecified value. Assume, for example, that that distance has changed (decreased) by one micron, due~ for example, to warpage in the wafer 40. A signal representative of the change is then sent to the computer 38 via lead 122. In response thereto, the computer applies a corresponding correction signal to the differential ampliier 72 (FIG. 1) included in the aforedescribed frequency control loop. In turn, a signal lS is applied by the amplifier 72 to the tuning and line-narrowing asslembly 54 to increase the center wavelength of the pulses emanating from the assembly 54. In one illustrative case, the center wavelength was increased by 0.1 ~. This was sufficient to decrease the focal distance of the lens 108 by one micron, thereby to compensate exactly for the assumed one-micron decrease in the lens-to-wafer spacing.

Claims (17)

Claims:

1. Apparatus for optical lithography, comprising stationary equipment including a laser source, equipment including a stepping table physically separated from said stationary equipment, and means for directing signals from said laser source in said stationary equipment to said second-mentioned equipment to maintain a prescribed alignment between the direction of propagation of said signals and said second-mentioned equipment even during movement of said second-mentioned equipment due to stepping of said table.

2. Apparatus as in claim 1 wherein said directing means comprises photodetector means mounted on said second-mentioned equipment responsive to laser signals from said source for generating electrical signals representative of said alignment, and deflection means in said stationary equipment responsive to said electrical signals for controlling the direction of propagation of said laser signals toward said second-mentioned equipment.

3. A method of maintaining the output beam of a laser aligned relative to movable equipment at which the beam is directed, said method comprising the steps of directing said beam at a photodetector array mounted on said movable equipment, said array being adapted to generate electrical signals representative of variations of said beam relative to a prescribed alignment with respect to said array, and applying said electrical signals via a feedback loop to a deflection assembly that maintains said beam aligned with respect to said array.

4. A method as in claim 3 wherein said laser beam comprises laser pulses and a continuous-wave laser signal propagated coaxially with said pulses, and wherein said array is responsive only to said continuous-wave signal for generating continuous electrical signals in said feedback loop.

5. An optical system, comprising:
a source of electromagnetic radiation:
equipment, including apparatus adapted to support a workpiece, said apparatus being physically separated from said source and said equipment being characterized by an axis which is nonparallel to a surface of said apparatus; and directing means for directing at least a portion of the radiation emitted by said source to said workpiece, said directing means including aligning means for maintaining a desired alignment between the directed radiation and said axis even during relative motion between said source and said equipment.

6. The optical system of claim 5 wherein said apparatus includes a stepping table.

7. The optical system of claim 5 wherein said source is capable of emitting radiation which includes deep UV radiation.

8. The optical system of claim 5 wherein said source includes a laser.

9. The optical system of claim 8 wherein said laser is an excimer laser.

10. The optical system of claim 9 wherein said excimer laser is a KrF excimer laser.

11. The optical system of claim 5 wherein said directing means includes a projection lens capable of optical communication with said source and said workpiece.

12. The optical system of claim 5 wherein said directing means includes a mirror capable of optical communication with said source and said workpiece, said aligning means including orienting means for altering an orientation of said mirror relative to said source in response to a deviation from said desired alignment.

13. The optical system of claim 12 wherein said orienting means includes a galvanometer motor mechanically connected to said mirror.

14. A method for fabricating a device, comprising the steps of:
mounting a workpiece on an apparatus adapted to support such a workpiece, said apparatus constituting a component of equipment characterized by an axis which is nonparallel to a surface of said apparatus;
directing electromagnetic radiation from a source of such radiation to said workpiece, said source being physically separated from said apparatus;
maintaining a desired alignment between said directed radiation and said axis even during relative motion between said source and said equipment; and further processing said workpiece to complete the fabrication of said device from said workpiece.

15. The method of claim 14 wherein said workpiece includes a substrate bearing photosensitive material.

16. The method of claim 14 wherein said substrate includes semiconductor material.

17. The method of claim 14 wherein said radiation includes deep UV radiation.