CN103558736A - 用于沉浸式光刻光学系统的清洗方法 - Google Patents

用于沉浸式光刻光学系统的清洗方法 Download PDF

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CN103558736A
CN103558736A CN201310419409.2A CN201310419409A CN103558736A CN 103558736 A CN103558736 A CN 103558736A CN 201310419409 A CN201310419409 A CN 201310419409A CN 103558736 A CN103558736 A CN 103558736A
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安德鲁·J·黑兹尔顿
川井秀实
道格拉斯·C·沃特森
托马斯·W·诺万克
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Abstract

一种用于沉浸式光刻光学系统的清洗方法,涉及的沉浸式光刻装置具有用于保持刻线板的刻线板台,用于保持工件的工件台,和位于工件对面、由照射源和光学元件组成的光学系统,用于通过照射源的辐射投影刻线板的图像。在光学元件和工件之间限定一个间隙,并且一个流体供应器件用于向该间隙内提供沉浸流体,从而在沉浸式光刻处理中使供应的沉浸流体与光学元件和工件均接触。具有一个清洗器件,其用于在清洗处理期间从光学元件除去吸附的液体。该清洗器件可以使用与被吸附液体具有亲和力的清洗液体、加热、真空条件、超声波振荡或者空化泡来除去吸附的液体。清洗液体可以通过相同的具有切换器件例如阀的流体施加器件加以提供。

Description

用于沉浸式光刻光学系统的清洗方法
本分案申请是基于申请号为2004800096916,申请日为2004年4月2日,发明名称为“用于沉浸式光刻光学系统的清洗方法”的中国专利申请的分案申请。更具体说,本分案申请是基于申请号为201010113560.X,申请日为2004年4月2日,发明名称为“用于沉浸式光刻光学系统的清洗方法”的分案申请的再次分案申请。
相关专利申请参考
本申请要求获得如下专利申请的优先权,即美国临时专利申请No.60/462,556,其于2003年4月11日提出申请,和美国临时专利申请No.60/482,913,其于2003年6月27日提出申请,本文引用其内容作为参考。
技术领域
本发明涉及一种沉浸式光刻系统,更特别地,除了系统之外,还涉及一种用于清洗在沉浸式光刻处理中接触并吸附水的光学元件的方法。
背景技术
沉浸式光刻系统用于向工件,例如晶片,和光学系统最后一级光学元件之间的空间内提供液体,用于将刻线板的图像投影到工件上面,这种沉浸式光刻系统如WO99/49504中公开的,本文引用其内容,用于说明该技术的一般背景以及与之有关的一些大体考虑。如此提供的液体能够提高光学系统的性能和曝光的品质。
用于波长为193nm的光线的待提供液体可以是水,尽管对于具有其它波长的光线可能需要不同的液体。因为光学系统最后一级光学元件暴露于液体,所以有可能会吸附一些液体。如果光学系统的最后一级光学元件是透镜,则这种可能性特别高,因为氟化钙是用于光刻系统的普通透镜材料,而它是易吸湿的材料,容易从周围环境中吸附水分。
被吸附的水分会导致多种问题。首先,它会改变透镜的折射性能或者使透镜膨胀从而改变透镜的几何尺寸,从而恶化由透镜投射的图像。其次,它可能由于化学效应导致透镜发生长期恶化。
传统的空气沉浸式曝光光刻系统要求光学元件可以拆卸,以便进行维护工作,例如进行清洗。
然而,除去光学元件以及在清洗之后重置它或者用新的光学元件替换该光学元件是一个繁琐而耗时的操作。
发明内容
因此,本发明的一个目的是提供一种系统和方法,其能够反复地清除透镜上的水从而使被吸附的水量不会达到临界值,进而防止图像恶化和透镜的长期破坏。
本发明的另一个目的是提供一种系统和方法,其使得维护沉浸式光刻装置的光学元件更容易,借此提供光学元件的可用寿命。
本发明的沉浸式光刻装置包括一个用于保持刻线板的刻线板台,一个用于保持工件的工作台,一个光学系统,其包括一个照射源和一个位于工件对面并通过照射源的辐射将刻线板的图像投影在工件上面的光学元件,同时在光学元件和工件之间限定一个间隙,和一个流体提供器件,其在沉浸式光刻处理期间,在光学元件和工件之间提供沉浸流体并使之相互接触。该装置还包括一个用于清洗光学元件的清洗器件。在本文中,术语“清洗”既用于表示清除吸附到光学元件中的液体,也用于表示清除灰尘、碎屑、盐等。
在本发明的范围内可以使用许多与前述不同类型的清洗器件。例如,它可以包括与待和光学元件接触的沉浸流体具有亲和力的清洗液体。如果沉浸液体是水,则可以使用乙醇作为清洗液体。作为另一个实例,清洗器件可以包括用于加热光学元件的发热器件和/或用于在光学元件上产生真空条件的真空器件。
超声波振荡可以用于清除被吸附液体。可以将超声波振荡器,例如压电换能器,附着在光学元件的外罩上或者放置在光学元件的对面,从而通过保持在间隙中的液体向光学元件发射振动。
选择地,可以使用空化泡(cavitating buble)清除被吸附的液体。一个有翼(fin)的衬垫用于在保持在衬垫和光学元件之间的间隙内的液体中产生空化泡。
根据本发明的再一个实施例,通过提供一个流路切换器件(flowroute-switching device),例如切换阀门,可以选择地使用喷嘴提供清洗液体,通过该喷嘴将沉浸液体供应到工件和光学元件之间的间隙内。
利用本发明的相同和方法,清洗处理变得相当容易而快速,因为不再需要拆卸待清洗的光学元件,并且该清洗处理提高了光学元件的使用寿命。
附图说明
通过联系附图参考下面的说明,可以最佳地理解本发明及其进一步的目的和优点,其中:
图1是可以采用本发明的方法和系统的沉浸式光刻装置的示意性剖面图;
图2是图解根据本发明使用图1所示装置制造半导体器件的示例性处理的处理流程图;
图3是在根据本发明制造半导体器件时,图2所示晶片处理步骤的流程图;
图4是显示图1所示沉浸式光刻装置一部分的侧视图;
图5是具有超声换能器作为清洗器件的另一个沉浸式光刻装置一部分的示意性侧视图;
图6是在光学系统下面具有压电清洗器件的另一个沉浸式光刻装置一部分的示意性侧视图;
图7是压电器件一个实例的示意图;
图8是具有两个相互固定的压电平面元件作为清洗器件的再一个沉浸式光刻装置一部分的示意性侧视图;
图9是具有发泡衬垫作为清洗器件的再一个沉浸式光刻装置一部分的示意性侧视图;和
图10是在流体供应器件内具有切换器件的另一个沉浸式光刻装置一部分的示意性侧视图。
在全部附图中,类似的或等价的部件在不同的附图中用相同的符号或数字表示,并且出于简化说明的目的,可以不再重复解释。
具体实施方式
图1显示了沉浸式光刻装置100,在其上面可以应用本发明的方法和系统。
如图1所示,沉浸式光刻装置100包括一个照射光学单元1,其包括一个光源例如受激准分子激光器单元,一个光学积分器(或者均化器)和一个透镜,该照射光学单元用于发射波长为248nm的紫外光IL,从而入射刻线板R上的图形。刻线板R上的图形通过远心光投影单元(telecentric light projection unit)PL以指定的放大率(例如1/4或1/5)投影到涂覆有光刻胶的晶片W上。脉冲光线IL可以选择的是波长为193nm的ArF受激准分子激光器激光,波长为157nm的F2受激准分子激光器激光,或者波长为365nm的汞灯i线。随后,在说明光刻装置100的结构和功能时,用图1所示的X-,Y-和Z-轴坐标系表示方向。为了便于公开和说明,在图1中,光投影单元PL仅图解了位于晶片W对面的最后一级光学元件(例如透镜)4和包含其余部件的圆柱形外罩3。
刻线板R支持在刻线板台RST上,该刻线板台包括一个用于沿着X方向和Y方向移动刻线板R并围绕Z轴旋转的机构。刻线板R在刻线板台RST上的二维位置和取向由激光干涉计(未显示)实时地检测,并且刻线板R的定位由主控制单元14根据该检测加以影响。
晶片W通过晶片固定器(未显示)固定在Z台9上,用于控制晶片W的聚焦位置(沿着Z轴)和倾角。Z台9固定在XY台上,该XY台适合于在基本上平行于光投影单元PL的成像表面的XY平面上移动。XY台10设定在基座11上。这样,Z台9通过自动聚焦和自动对准(leveling)方法调节晶片W的聚焦位置(沿着Z轴)和倾角,用于使晶片表面与光投影单元PL的图像表面相匹配,并且XY台10用于沿着X方向和Y方向调节晶片W的位置。
Z台9(因此也称作晶片W)的二维位置和取向通过另一个激光干涉仪13并参考固定于Z台9上的可动反射镜实时地加以监视。基于该监视的控制数据从主控制单元14发送到台驱动单元15,该台驱动单元适合于根据所接收的控制数据控制Z台9和XY台10的运动。在曝光时,投影光线根据刻线板R上的图形以步进-重复(step-and-repeat)的程序或者以步进-扫描的(step-and-scan)程序顺序地从晶片W上的一个曝光位置移动到另一个曝光位置。
参考图1说明的光刻装置100是一个沉浸式光刻装置,因此至少在将刻线板R上的图形投影到晶片W上时,其适合于用特殊种类的液体(或者“沉浸液体”)7,例如水,充满晶片W的表面与光投影单元PL最后一级光学元件4的下表面之间的空间(“间隙”)。
光投影单元PL的最后一级光学元件4可以可拆卸地固定在圆柱形外罩3上,并被设计成使液体7只接触最后一级光学元件4而不接触圆柱形外罩3,因为外罩3典型地用金属材料制成,并且容易腐蚀。
液体7在控温的条件下从液体供应单元5提供到晶片W上方的空间并通过液体回收单元6加以收集,该液体供应单元可以包括一个储罐、一个压力泵和一个温度调节器(未单独显示)。液体7的温度被调节成与放置光刻装置100的室内的温度近似相同。数字21表示供应喷嘴,液体7通过它从供应单元5加以提供。数字23表示回收喷嘴,液体7通过它被收集到回收单元6内。然而应当记住,上述参考图1的结构并不对可以应用本发明的清洗方法和器件的沉浸式光刻装置的范围构成限制。换言之,不必问,本发明的清洗方法和器件能够应用于许多不同类型的沉浸式光刻装置。特别地,应当记住,围绕光投影单元PL的供应和回收喷嘴21和23的数目和布置可以按照不同的方式加以设计,以便建立沉浸液体7的平滑流动和快速回收。
下面参考图1和4解释实现本发明的清洗方法,该方法可以除去被由易吸湿材料制成的最后一级光学元件4吸附的部分液体7,例如水,以及灰尘、碎屑等。如图1所示,在液体7存在的情况下,通过光投影单元PL用照射光学单元1的光线曝光晶片W之后,将液体7从光投影单元PL的下方除去,并使清洗器件30与最后一级光学元件4相互接触,如图4所示。在便携式类型的实力中,如图4所示,清洗器件30可以布置在Z台9或者前述的晶片固定器上,如图4所示,替换晶片W。
出于本发明的目的,可以使用不同型号和种类的清洗器件30。作为第一个实例,清洗器件30可以是一个盛有与被光学元件4吸附的沉浸液体7具有强亲和力的液体(“清洗液”)的容器。如果沉浸液体7是水,那么清洗器件30可以容纳乙醇,因为乙醇与水具有强亲和力。任何清洗液体都可以使用,只要它与待清除的液体具有强亲和力且不会破坏光学元件4及其涂层即可。光学元件4的两个表面都浸没在清洗液中一段时间,直到足以除去被吸附液体的水平。之后除去清洗器件30,光学元件4准备好再一次暴露于液体7。
作为另一个实例,清洗器件30可以包含一个发热器件和/或真空器件(未分离显示)。热和真空在光学元件4表面上的组合使得被吸附液体发生相变成为气体,或者从表面上蒸发。光学元件4表面上液体密度的降低使更深层吸附在元件4内的液体7到达表面。
图5显示了第三个实例,其中使用了附着在光投影单元PL的外罩3上的超声换能器(或者超声波振荡器)32。随着超声换能器32(例如压电换能器)被激活,产生并传播压力波,用于清洗光学元件4的表面。
在图5的清洗操作期间,邻近光学元件4的间隙内充满沉浸液体7。在这种情况下,供应和回收喷嘴能够连续地提供和收集沉浸液体7,或者供应和回收喷嘴能够停止供应和收集沉浸液体7。同样在清洗操作期间,光学元件4能够面对晶片W的表面,Z台9的表面或者另一个组件的表面。
图6是在待清洗的光学元件下面使用振荡工具34的第四个实例。工具34的形状可以和晶片W相似,厚度大致等于晶片W的厚度,或者大约未0.5-1mm,并且可以完全用压电材料制成,从而其厚度在被激活时会波动。因为工具34位于光学元件4的下面,类似于图1所示的晶片W,并且光学元件4和工具34之间的间隙内充满液体7,所以在沉浸液体7内产生压力波从而清洗光学元件。
在图6的清洗操作期间,邻近光学元件4的间隙内充满沉浸液体7。这种情况下,供应和回收喷嘴能够连续地提供和收集沉浸液体,或者供应和回收喷嘴能够停止供应和收集沉浸液体7。在其它实例中,振荡器34可以是一个位于Z台9或者其它组件上的附着在晶片固定器上的超声换能器。
图7显示了另一个具有不同结构的工具36,其具有多个用平面支持元件39支持的压电换能器38。
图8显示了清洗器件另外的一个实例,其具有两个以面对面的方式附着在一起的并适合于彼此平行振荡并且相差为180°的压电材料平面元件40。结果,这些元件40彼此附着在一起沿着横向振荡,图8以夸大的方式加以显示。该振荡以恒定的间隔在没有防止元件40的位置具有节点。元件40在这些节点处被支持在支持元件41上。当向这些元件40施加电压使之以上述方式产生振荡时,通过液体7产生并传播超声压力波,从而按照期望清洗光学元件4。
图9显示了液体清除系统的再一个实例,其特点是通过产生空化泡清洗光学元件4。由超声波俘获和赋能的空化泡是高温高压的微反应器,由气泡的内爆压缩(implosive compression)释放的强大能量被认为能够将分子拨开。图9所示实例的特点是包括一个衬垫43,其具有向上突出的翼,并且如光学元件4下面的箭头所示地水平快速移动,同时用发泡液体7填充其间的间隙9(用于移动衬垫43的装置,未显示)。随着如此移动衬垫43,翼用于搅动液体17并产生用于清洗光学元件的空化泡。
图10显示了一种解决清洗最后一级光学元件4的问题的不同方法,其是通过使用与提供沉浸液体7同源的喷嘴21在其底表面上施加清洗液。出于这个目的,在供应喷嘴21和液体单元5之间插入切换阀门25,从而能够使沉浸液体7和清洗液选择地通过供应喷嘴21。
要再次记住,根据本发明的清洗方法和系统能够应用于不同类型和种类,也就是,具有不同数目源喷嘴,的沉浸式光刻装置。上述的切换阀门不需要提供给每个源喷嘴,而是可以提供给一组源喷嘴。
当如此通过供应喷嘴21提供清洗液时,也许适合于放置在光学元件4下方的晶片W本身或者衬垫18能够在其间提供合适的间隙。本发明的这一实施例是有利的,因为能够使用已有的用于提供沉浸液体的相同喷嘴进行清洗处理。
尽管上面分别说明各种方法,当时无需说明也应理解,它们也可以组合使用,尽管附图中并没有分别显示。例如,图9所示具有翼的衬垫43可以代替图10所示的衬垫18。换言之,上述的实例并不限制本发明的范围,在本发明的范围内可以有许多的修饰和改变。例如,可以使用类似于在化学机械抛光处理中使用的抛光衬垫实现本目的。图4-10显示的清洗程序可以用紫外光执行。光线可以辐照光学元件4。该光线可以是来自照射光学元件4的正常曝光光线,或者其它具有适合于清洗的波长的光线。在其它实例中,可以使用用于清洗的紫外光,而不用图4-10所示的清洗程序,并且可以在如下的条件下使用,即邻近光学元件4的间隙内充满来自液体供应单元5的沉浸液体7。所有这些修改和变化对于本领域的技术人员而言都是显而易见的,并且都在本发明的范围之内。
再一次,应当注意,任何上述的清洗方法既可以用于清除被最后一级光学元件吸附的沉浸液体,也可以用于清除有可能积累的盐、沉积物、灰尘和碎屑。因此术语清洗在这里包括这两种现象。
下面参考图2说明使用实现本发明的包括液体喷射和回收系统的沉浸式光刻装置制造半导体器件的处理。在步骤301,设计器件的功能和性能特征。接着在步骤302,根据先前的设计步骤设计具有图形的掩模(刻线板),在平行的步骤303中,用硅材料制造晶片。在步骤304,通过平板照相系统,例如上述的系统,将在步骤302中设计的掩模图形曝光到在步骤303中制造的晶片上。在步骤305,组装半导体器件(包括切片处理,键合处理和封装处理),然后在步骤306检查最终的器件。
图3图解了在制造半导体器件时上述步骤304的详细流程实例。在步骤311(氧化步骤),晶片表面被氧化。在步骤312(CVD步骤),在晶片表面上形成绝缘膜。在步骤313(电极形成步骤),通过气相沉积在晶片上形成电极。在步骤314(离子植入步骤),在晶片内植入离子。前述的步骤311-314形成了晶片处理期间的预处理步骤,并且在每一步都可以根据需要进行选择。
在晶片处理的每个阶段,当上述预处理步骤完成时,执行如下的后处理步骤。在后处理期间,在步骤315(光刻胶形成步骤),将光刻胶施加到晶片上。接着在步骤316(曝光步骤),使用上述的曝光器件将掩模(刻线板)上的电路图转移到晶片上。然后在步骤317(显影步骤),对曝光晶片进行显影,并且在步骤318(腐蚀步骤),通过腐蚀除去除残余光刻胶之外的部分(曝光材料表面)。在步骤319(光刻胶清除步骤),除去在腐蚀之后剩余的不必要光刻胶。通过重复这些处理和后处理步骤可以形成多个电路图。
尽管本发明的光刻系统是通过多个优选实施例加以说明,但是可选择的、可置换的和各种可替代的等价物也在本发明的范围内。还应当注意,存在许多可选择的方法用于实现本发明的方法和装置。因此,如下的权利要求包括所有这些处于本发明精神和范围之内的可选择的、可置换的和各种可替代的等价物。

Claims (12)

1.一种用于沉浸式光刻装置的清洗方法,其中在沉浸式光刻处理期间,用于光刻的工件位于台上,具有光学元件的投影光学系统在所述工件的上方并与之相对,在所述光学元件与所述工件之间提供间隙,所述方法包括如下步骤:
在清洗处理期间将清洗器件置于所述台上;以及
在所述清洗处理期间在所述光学元件与于所述台上的所述清洗器件之间供应液体,所述光学元件在所述清洗处理期间与所供应的液体接触。
2.根据权利要求1的清洗方法,其中所述清洗处理在所述沉浸式光刻处理之后进行。
3.根据权利要求1的清洗方法,其中在所述清洗处理期间所供应的所述液体是水。
4.根据权利要求1的清洗方法,其中所述液体的供应与所供应的液体的收集在所述清洗处理期间继续进行。
5.一种沉浸式光刻装置,其中,在沉浸式光刻处理期间,在光学元件与用于光刻的工件之间提供间隙,所述沉浸式光刻装置包括:
台,用于光刻的所述工件在所述沉浸式光刻处理期间保持于其上,并且清洗器件在清洗处理期间置于其上;
具有所述光学元件的投影光学系统,其在所述沉浸式光刻处理期间是在所述工件的上方并与之相对;以及
喷嘴,被设置为在所述沉浸式光刻处理期间向在所述光学元件与于所述台上的所述工件之间的所述间隙供应沉浸液体,并且被设置为在所述清洗处理期间向所述光学元件与于所述台上的所述清洗器件之间的间隙供应液体,所述光学组件在所述清洗处理期间与所供应的液体接触。
6.根据权利要求5的装置,其中所述清洗处理在所述沉浸式光刻处理之后进行。
7.根据权利要求5的装置,其中在所述清洗处理期间所供应的所述液体是水。
8.根据权利要求5的装置,其中所述液体的供应与所供应的液体的收集在所述清洗处理期间继续进行。
9.一种器件制造方法,包括:
通过权利要求5-8中任一项的装置曝光晶片;以及
显影所曝光的晶片。
10.一种用于沉浸式光刻装置的清洗方法,所述方法包括:
在清洗处理期间将投影光学系统的光学元件浸没在一种液体中;以及
在所述清洗处理期间将光执行施加于所述光学元件。
11.根据权利要求10的清洗方法,其中所述光是紫外光。
12.根据权利要求11的清洗方法,其中所述光是曝光光线。
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