CN1550902A - 改进的图形发生器反射镜结构 - Google Patents
改进的图形发生器反射镜结构 Download PDFInfo
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Abstract
本发明涉及到一种用来在对辐射敏感的工件上产生诸如光掩模、显示屏或微光学器件之类的图形的装置。此装置包含辐射源和具有多个调制元件/象素的空间调制器。它还包含将驱动信号馈送到调制器的电子数据处理和发送***、用来移动所述工件的精密机械***、以及对工件的运动、到调制器的信号馈送和辐射的强度进行协调以便将分图形顺序产生的分图象缝合成所述图形的电子控制***。根据本发明,驱动信号能够将调制元件设定到多于2的多个状态。
Description
本申请是申请日为1999年3月2日、申请号为99803477.0、发明名称为“改进的图形发生器”的发明专利申请的分案申请。
技术领域
本发明涉及到在诸如半导体器件和显示器的光掩模之类的光敏表面上印制精度极高的图形。还涉及到半导体器件图形、显示屏、集成光学器件以及电子互连结构的直接写入。而且能够应用于诸如保密印刷之类的其它类型的精密印刷。应该广义地理解印刷这个术语,它意味着光刻胶和照相乳胶的曝光以及借助于光或热激发的烧蚀或化学过程而在诸如干法印相纸之类的其它光敏媒质上的光作用。光不局限于可见光,而是包括从红外(IR)到远紫外UV的广阔范围的波长。特别重要的是从370nm(UV),通过远紫外(DUV)、真空紫外(VUV)和超紫外(EUV)直至几毫微米波长的紫外范围。在本申请中,EUV被定义为从100nm以下直至有可能以光的形式来处理的辐射的范围。EUV的典型波长为13nm。IR被定义为780nm直至大约20微米。
另一方面,本发明涉及到空间光调制器以及采用这种调制器的投影显示器和印相机的技术。确切地说,借助于模拟调制技术,改进了这种调制器的灰度性质、通过焦点的图象稳定性和图象均匀性以及数据处理。模拟调制的最重要的应用是用来在诸如具有地址网格亦即比空间光调制器象素产生的网格精细得多的用以规定图形中的边沿位置增量的光刻胶之类的高对比度材料中产生图象。
背景技术
在本技术领域中已知用微镜类型的微镜空间光调制器(SLM)的投影来建立精密图形发生器(Nelson 1988:美国专利US 5148157,Kück1990:欧洲专利EP 0610183)。比之使用扫描激光斑点的更广为使用的方法来说,在图形发生器中使用SLM具有大量优点:SLM是整体并行器件且每秒钟能够写入的象素的数目非常大。在SLM的照明不严格,而激光扫描仪中整个光束路径必须具有高精度的意义上,光学***也更简单。比之某些类型的扫描仪,特别是电光和声光扫描仪,微镜SLM由于是纯反射器件而能够在更短的波长下使用。
在上述二个参考文献中,空间调制器仅仅使用各个象素的开通-关断调制。输入数据被转换到具有一位深度,亦即各个象素中具有数值0和1的象素图。利用图形处理器或具有区域填充指令的用户逻辑,能够有效地实现这一转换。
在同一个发明人Sandstrom的早先的一个申请中(Sandstrom等人,1990:欧洲专利EP 0467076),描述了使用图形元件边界处的中等曝光数值精细调节激光扫描仪产生的图象中元件边界位置的能力。
在本技术领域中,还已知利用SLM,借助于改变象素被开通的时间或借助于用开通不同次数的象素几次印刷同一个象素,来更好地产生视频图象的投影显示和印刷的灰度图象。本发明制作了具有空间光调制器的用于直接产生灰度特别是产生超精密图形的***。各个最佳实施例中的重要情况是各个象素之间的图象均匀性和部件相对于SLM象素的准确位置的独立性以及当焦点有意或无意被改变时的稳定性。
发明内容
因此,本发明的目的是提供一种用来印刷精密图形的改进了的图形发生器。
利用根据所附权利要求的装置,提供SLM中的象素的模拟调制,达到了此目的。
附图说明
图1示出了现有技术的印相机。SLM由使来自透镜光孔的光发生偏移的微镜组成。
图2示出了多个象素设计,上面4个象素处于关断状态,而其余5个象素开通。
图3示出了像活塞那样上下运动从而产生相位差的象素阵列。这就是用相位型SLM能够精细定位边界的原因。
图4示出了具有偏转反射镜的SLM与具有变形反射镜的SLM之间的示意比较。
图5示出了将数据转换和馈送到SLM的方法的流程图。
图6示出了根据本发明的图形发生器的最佳实施例。
图7示意地示出了不同类型SLM的可能复振幅。
图8示意地示出了SLM反射镜的不同类型的控制。
具体实施方式
图1中的通常配置是理解本发明的基础,它示出了具有SLM的一般投影印相机。基于反射的空间光调制器有二种,偏转型(Nelson)和相位型(Kück)。它们之间的差别可能在于看起来很小的微镜的具体情况,但相位SLM借助于相消干涉来消除反射方向的光束,而偏转SLM中的象素在几何学上将反射光束偏转到一侧,致使如图1所示不命中成像透镜的光圈。对于如本发明执行的超精密印相,Kück 1990所述的相位调制***优越于偏转类型。首先,由于表面的所有部件以及连接和支持部分都参与相消干扰而能够达到完全消光,故具有更好的对比度。第二,借助于将光偏转到一侧而工作的***难以在中等偏转角度下绕光轴形成对称,在焦点改变时,产生图形不稳定的危险。在最佳实施例中使用了相位型,但若接受和设计在偏转型的不对称周围,则也能够被使用。图4示意地示出了这一点。在图4a中,对不偏转的微镜401进行照明,反射光不被引导到光圈402,因此,光不到达基底403。另一方面,在图4b中,反射镜被完全偏转,且所有的反射光被引导到光圈。如图4c所示,在中间位置,只有部分反射光将到达基底。但此时光不绕透镜404的光轴对称,从而在基底上有倾斜的入射。因此,透镜与基底区域之间的距离变得很关键,且诸如虚线区域位置所示的小的面积变化就引起图形在基底上的明显的位移。解决此问题的方法示于图4d-f。此处,用微镜的第一偏转角度进行第一曝光,然后最好用同一个光剂量进行与第一角度互补的第二偏转角度的第二曝光。从而第一和第二曝光的组合绕透镜的光轴对称。解决此问题的另一方法是使用如图4g所示的变形反射镜401′,从而反射光均匀地分布在光圈上。此最后一个图能够示意地表示相位型SLM(下面描述)或光从反射镜的不同部分被反射的偏转SLM二种情况。
用所谓微镜的微机械加工的反射镜,或用能够用电子信号变形的支持基底上的连续反射镜表面,能够建立相位SLM。在文献Kück 1990中,采用了一种受静电场控制的粘弹性层,但特别是对于大约几毫微米的形变就足够了的非常短的波长来说,同样有可能采用被电场变形的压电固体盘或另一种电学、磁学或热学控制的反射表面。虽然诸如依赖于作为其调制机制的LCD晶体或电光材料的透射或反射SLM或采用压电或电致驱动的微机械SLM之类的上述的其它安排是可能的,但对于其余的这种应用,设想了一种静电控制的微镜矩阵(一维或二维)。
为了获得到达投影透镜光孔的可变化的光量,本发明最好使用相位调制可变化的微镜。图2示出了一些多元反射镜。反射镜各个部分的倾斜是不重要的。实际上,一个元件本身将光引导到透镜,而另一个将光引导到光孔外面。理解此功能的正确方法是注意从反射镜的各个无限小区域元件到达光孔中心的复振幅并在反射镜上累计此幅度。利用适当形状的反射镜,有可能找到复振幅加起来几乎为0的变形,对应于没有光到达光孔。这是微镜的关断状态,而反射镜表面平坦且复振幅同相位相加的弛豫状态是开通状态。在开通与关断状态之间,沿反射方向的光量是形变的连续非线性函数。
待要写入的图形通常是诸如玻璃基底上铬的光掩模图形之类的二元图形。在这种情况下,二元意味着不存在中间区域:光掩模表面上的某个点要么是暗(被铬覆盖),要么是亮(无铬)。此图形被来自SLM的投影图象曝光在光刻胶中,并对光刻胶进行显影。现代光刻胶具有高的对比度,意味着曝光的小的改变就形成光刻胶在显影液中完全清除与完全不清除之间的差别。因此,即使空间图象具有亮暗之间的逐渐过渡,光刻胶也具有通常几乎垂直于基底表面的边沿。铬腐蚀进一步增加了对比度,致使得到的图象是完美的二元:要么暗要么亮,没有中间区域。
输入数据是数字格式,表示待要写入在表面上的图形的几何形状。此输入数据常常被给定在例如1毫微米的非常小的地址单元中,而将SLM中象素设定为开通或关断则给出大得多的图形。若SLM上的象素被投影成图象中的0.1微米象素,则线能够仅仅具有象素整数倍的宽度(n*0.1微米,其中n为整数)。迄今,0.1微米的地址网格就足够了,但所谓光学邻近效应效正OPC的出现,使得1-5毫微米的网格成为可取的。在OPC中,掩模中图形的尺寸被稍许修正,以便补偿使用掩模时的预计光学图象误差。作为一个例子,当具有4个0.8微米宽的平行线的掩模在现代4X缩小步进机(用于半导体晶片的一种投影印相机)中被印制时,虽然希望它们具有相同的宽度,但典型情况下将被印制成宽度为0.187、0.200、0.200和0.187微米。借助于图象模拟能够预计这一点,且掩模用户可以使用OPC来补偿掩模。因此需要掩模中的第一和第四线为4*0.213=0.852微米,而不是0.800微米。利用0.1微米的地址网格无法进行修正,但利用5毫微米或更精细的地址网格,有可能进行这样的修正。
在图5中,在流程图中示出了提供SLM的数据的方法。第一步骤S1是将待要写入的图形的图形数据分成分隔的图形场。此图形数据最好以数字形式接收。然后,在步骤S2中,对各个场进行扫描,从而规定不同的曝光数值。然后在步骤S3中,对这些数值进行非线性响应修正,并在步骤S4中逐个改变象素。最后,象素数值被转换成驱动信号并馈送到SLM。
为了产生例如1/15、1/25、1/50象素尺寸的精细的地址网格,本发明最好地使用了关断状态与开通状态之间的中间数值。被印制的图形由处于开通状态的象素组成,但沿着边沿具有设定在中间数值的象素。借助于用开通和关断电压之外的其它电压驱动象素,做到了这一点。由于有几个级连的非线性效应(边沿位置对边界处象素的曝光、曝光对形变、以及形变对电场),故需要从输入数据到电场的非线性转换。而且,此转换在定期的时间间隔内被实验校正。
图3示出了像活塞那样上下运动从而产生相位差的象素组成的阵列。此图示出了如何控制象素来产生插图中的反射率。亮区具有0相位的象素,而暗区由具有改变+90和-90度相位的象素产生。亮区与暗区之间倾斜的边界由相位的中间数值产生。这就是能够用相位型SLM来精细定位边沿的原因。但也能够以相同的方式使用具有中间数值的其它类型的SLM。具有驱动成中间数值的相位SLM的成像性质是复杂的,且远不能看出图3中边沿会移动。但本发明人进行的深入的理论计算和实验已经表明,上述的效应是真实的。
如图3所示,为了产生精细的地址网格,采用电子处理***来产生图形内部的一种象素图、图形外面的另一种象素图以及边界处的中间象素图,其中边界处的中间象素图依赖于网格中边界的位置而产生在比投影在工件上的SLM的象素图更精细的网格中。SLM和投影***产生图形内部的一种曝光等级、图形之间的另一种曝光等级以及边界处的中间曝光等级。利用SLM对多个状态的调制能力来产生中间曝光等级。驱动信号对边界实际位置的响应被测试并修正。对其进行实验测量并计算校正函数,再存储在数据处理和发送***中。
为了进一步改善地址分辨率,平台和SLM被用来沿不平行于SLM坐标***的通常为45度的方向将各个曝光场缝合到一起。确切地说,平台或光学***沿不平行于SLM但通常与SLM坐标***成45度角的方向发生连续运动。SLM也可能具有不正交的轴,此时没有平行于运动方向的轴是有利的。而且,为了抑制矩阵本身线误差的SLM的列和行驱动器中的缺陷引起的线误差,使行和列线与缝合方向亦即被缝合的场之间的向量成一角度是有效的。
借助于用被修正的数据覆盖至少二次曝光,使组合的曝光具有在单一曝光中不可能得到的中间数值,产生了地址网格的额外改进。
相位型SLM的设计
图2c所示现有技术使用的苜蓿叶形反射镜设计,有可能驱动开通与关断状态之间的中间状态。但当合计的复振幅被绘制成偏离量的函数时,可以看到决不完全为0,而是在围绕着0的圆圈内,因此具有变化的相位角的非0最小反射率。在图7中用线701示意地示出了这一点,其中703表示某些形变数值的位置,而φ是相关的相位角。对具有某些设定在中间状态的象素的图象仔细分析表明,若边沿象素合计的相位角不为0,则最终图象中的各个边沿的位置不稳定通过焦点。这是相似于图4所示反射效应的衍射效应。在本发明的最佳实施例中,使用了一种新的具有旋转中心元件的象素。图2e-h示出了这种元件的例子。当元件旋转中心一端向光源运动而另一端离开光源时,它保持接近0的平均相位。图7中的虚线702示意地示出了这一点。而且,苜蓿叶形设计有制造过程中产生的内建应力的问题。此应力倾向于在无外加电场的情况下给出空间形变。内建形变由于依赖于制造过程中的不完整性而在各个象素中不完全相同。在苜蓿叶形设计中,这一逐个象素之间的差别产生反射率的一阶变化。由旋转中心元件建立的象素单元也出现相同的效应,但给出二阶效应。因此,投影图象的均匀性更好。
对于图形中不同定位的和/或不同取向的边沿,调制元件和曝光方法的设计被用来产生投影***光圈挡板的对称性。借助于用象素网格相对于图形的不同位置来覆盖至少二个图象,能够降低相对于象素网格位于不同位置处的边沿之间的固有不对称性。
对于偏转型SLM,对称性与光圈挡板中的强度分布有关。最好是具有将光相对于光圈挡板的中心对称地偏转或能够用产生对称性的互补偏转覆盖曝光的调制元件。利用具有可控制偏转的调制元件,有可能产生边沿象素处的偏转与边沿之间的恒定的几何关系,亦即沿垂直于边沿和向着图形内部的方向引导。
利用衍射型SLM,有可能借助于用相反的相位图覆盖曝光而产生对称性。若在SLM上复振幅各处都是实数,则能够保持对称性,且能够设计象素,使合计复振幅基本上为-1到1范围中的实数。多数情况下幅度为-0.5到1就足够了。这正是图2e、f、g、h中的正方形旋转中心微镜元件的情况。
利用存取一个小的负幅度以便印制背景区域,有可能提高分辨率。在更复杂的方案中,有可能驱动相邻象素组组合在图象中,并在用成像***过滤之后给出所需的实数幅度。
为了保留对称性,具有至少二重对称和最好是四重对称是有利的。借助于多次覆盖曝光,能够使不具有固有旋转对称的象素产生对称性。而且,能够用给出可控制的实数幅度的象素设计或曝光顺序来提高分辨率。暗线若位于相位相反的区域之间,则能够给出极大的对比度,且借助于将图形内部的相邻象素驱动到更高的正幅度,或将外面的相邻象素驱动到负幅度,能够改善图形的边沿。
图象增强
旋转中心设计具有第三优点:苜蓿叶达不到完全消光,但旋转中心单元能够更容易地给出完全消光的几何形状,或甚至通过0并回到相位相反的小的非0反射。更好的消光具有印制覆盖曝光的更大的自由度,设计小的负数值702提供了接近消光的更好的线性。在暗区以相反的相位的大约5%的弱曝光进行印制,能够提供15-30%的更高的边沿锐度和以给定的透镜印制更小的图形的能力。这相似于半导体工业中所用的所谓衰减相移掩模。提高边沿锐度的有关方法是将图形内部的象素设定为更低的数值而靠近边沿的象素设定为更高的数值。这提供了从掩模或利用Nelson和Kück投影器的现有图形投影不可能得到的一种新的图象增强方法。由于效果是附加的或至少是可计算的,故背景中的非0负振幅与沿边沿提高了的曝光不必与借助于驱动边沿象素到中间数值而产生精细地址网格相冲突。当象素明显地小于待要印制的图形时,存在着同时产生所有效果的象素数值的组合。为了找到它们,需要比单独产生精细地址网格更多的计算,但在本发明的某些应用中,印制更小的图形的能力能够具有为额外努力所付出的高的价值。
在粘弹性层上的连续反射镜的情况下,存在着平均相位与0的固有平衡。模拟已经显示,为图形边沿的精细定位而驱动到中间数值,对连续反射镜也可行。非线性比微镜小。但为了方法好用,最小的图形必须大于微镜,亦即每个被分辨的图形元件具有更多的被寻址象素。结果是SLM器件更大,且对于给定的图形的数据量更大。因此,在第一和第二实施例中已经选择了微镜。
在本发明中,由于二个理由而采用了具有旋转对称形变(至少二重对称,在最佳实施例中为四重对称)的象素:提供投影透镜光孔的对称照明以及使图象对旋转不敏感。对于在半导体晶片上印制随机逻辑图形来说,后者是重要的。若存在x-y不对称,则沿x轴布局的晶体管将具有与沿y轴的晶体管不同的延迟,电路可能工作不正常或仅仅能够用于较低的时钟速度。图象通过焦点不变化以及x与y之间的对称性这二个要求,使在光学***中产生和保持对称性非常重要。对称性可以是固有的,或借助于诸如利用具有互补不对称性质的多次曝光之类校正不对称性质的平衡而产生。但由于多次曝光导致产率下降,故固有对称布局更有利得多。
最佳实施例
第一最佳实施例是一种使用2048×512微镜的光掩模的远UV图形发生器。光源是KrF准分子激光器,其脉冲输出为248毫微米,脉冲长度约为10ns,而重复速率为500Hz。SLM具有反射90%以上的光的铝表面。用激光器通过束编码照明器对SLM进行照明,反射的光被引导到投影透镜并进一步引导到光敏表面。来自照明器的入射束和到透镜的出射束,被半透明光束***器反射镜分隔开。此反射镜最好是偏振选择的,且照明器使用偏振光,其偏转方向由SLM前面的四分之一波长片转换。对于高NA的x和y对称,图象必须对称地偏振,且光束***器与投影透镜之间的第二个四分之一波长片产生圆偏振图象。当激光器脉冲能量允许使用非偏振光束***器时,装置更简单。第二次通过光束***器之后的四分之一波长片由于使光束***涂层的设计更不敏感而仍然有优点。其中最简单的安排是使用SLM处的倾斜入射,使来自照明器和到投影透镜的光束如图1所示被几何学上分隔开。
微镜象素为20×20微米,而投影透镜的缩小倍数为200,使SLM上的开通象素相当于图象中的0.1微米。透镜是NA为0.8的单色DUV透镜,提供0.17微米FWHM的点扩展函数。能够被高质量写入的最小的线是0.25微米。
用透镜下方的干涉计控制的平台使工件例如光掩模运动,而到激光器的干涉计逻辑信号产生闪烁。由于此闪烁仅仅为10ns,故平台的运动在曝光过程中被冻结,且SLM的图象被印制,尺寸为204.8×51.2微米。2毫秒之后,平台移动51.2微米,发射一个新的闪烁,且新的SLM图象与第一个逐个边到边被印制。在曝光之间,数据输入***已经将新的图象载入SLM中,致使更大的图形由缝合各个闪烁组成。当整个行被写入之后,平台沿垂直方向前进,于是开始新的一行。虽然第一最佳实施例通常写入125×125mm的图形,但用此方法能够写入任何尺寸的图形。为了写入这种尺寸的图形,需要50分钟外加在相邻列之间运动的时间。
各个象素能够被控制到25个等级(外加0),从而将0.1微米的象素***到各为4nm的25个增量中。数据转换对图形进行几何分类,并转换成具有设定为开通、关断、或中间反射的象素的分布图。数据路径必须向SLM馈送每秒2048*512*500字的数据,实际上是每秒524兆位象素数据。在最佳实施例中,可写入的区域最大为230×230mm,在一列中最多提供高达230/0.0512=4500个闪烁,且此列在4500/500=9秒钟内被写入。一列中所需的象素数据量为9×524=4800兆位。为了减少传送和缓冲的数据量,采用了压缩格式,与Sandstrom等人90中的相似,但差别是象素图被压缩而不是具有长度和数值的各个区段。一种可行的变通是即时产生象素图并使用市售的压缩和解压硬件处理器来减少待要传送和缓冲的数据量。
即使利用压缩,整个掩模中的数据量也使得在盘上存储预先分离的数据很不实际,必须在使用时产生象素数据。处理器阵列以并行方式将图象扫描成压缩格式,并将被压缩的数据传送到扩展器电路,将象素数据馈送给SLM。在最佳实施例中,处理器扫描图象的不同部分,并在将它们传输到扩展器电路的输入缓冲器之前对结果进行缓冲。
第二最佳实施例
在第二最佳实施例中,激光器是波长为193nm而脉冲频率为500Hz的ArF准分子激光器。SLM具有3072×1024个20*20微米的象素,而透镜的缩小倍数为333,提供0.06微米的投影象素。有60个中间数值,且地址网格为1nm。点扩展函数为0.13微米,而最小线为0.2微米。数据流为1572兆位/秒,而230mm长的一列中的数据为11.8Gb。
第三最佳实施例除了象素矩阵旋转45度且象素网格为84微米,沿x和y提供0.06微米的投影象素间距外,与第二实施例完全相同。激光器是ArF准分子激光器,而透镜的缩小倍数为240。由于旋转的矩阵,故矩阵中象素的密度更低,且数据量是前述实施例的一半,但具有相同的地址分辨率。
激光器闪烁之间的变化
准分子激光器具有二个不希望有的性质,闪烁之间5%的能量变化以及闪烁之间100ns的时间间隙。在最佳实施例中,二者以相同的方法被补偿。用90%的功率进行整个图形的第一曝光。各个闪烁的实际闪烁能量和时间位置被记录下来。用标称10%的曝光,并用根据第一曝光的实际数值进行5-15%的第二曝光的模拟调制,进行第二曝光。第二曝光中的校正时间偏离也能够补偿第一曝光的时间间隙。第二曝光能够完全补偿第一曝光中的误差,但其本身将给出同样类型的新的误差。由于总的曝光仅仅平均为10%,故二个误差被有效地降低了10倍。实际上,由于光脉冲经过触发器脉冲的延迟,且此延迟随时有几微秒的变化,故激光器具有比100ns大得多的时间不确定性。在短的时间内,此延迟更稳定。因此,连续地测量延迟,并将恰当地过滤了的最后的延迟数值用来预示下一个脉冲延迟并定位触发器脉冲。
有可能以相同的方法来修正平台的不完整性,亦即,若平台误差被记录,则平台被第二曝光中的补偿运动驱动。原则上能够以这一方法来部分或完全地修正能够测量的任何位置误差。在第二曝光过程中,必须具有快速伺服马达来将平台驱动到计算得到的位置。在现有技术中,已知将SLM本身安装在具有小冲程和短响应时间的平台上,并用它来精细定位图象。另一个同样有用的方案是,在SLM与图象表面之间的光学***中使用具有压电控制的反射镜,二者之间的选择根据实际考虑来决定。也有可能将位置偏离加入到曝光场的数据中,从而横向移动图象。
最好用激光器与SLM之间的衰减滤波器来进行第二曝光,使SLM的整个动态范围能够被用在标称曝光的0-15%的范围内。利用25个中间等级,有可能以15%*1/25=0.6%的步长来调整曝光。
由于制造缺陷和潜在的老化,响应在象素之间稍有变化。其结果是图象的不希望有的不均匀。图象要求非常高时,可能必须借助于用存储在查寻存储器中的象素反转响应度的放大来修正各个象素。对各个象素采用具有2项、3项或更多项的多项式则更好。在驱动SLM的逻辑硬件中能够完成这一点。
在更复杂的最佳实施例中,几个修正被组合成第二修正曝光:逐个闪烁之间的变化、闪烁时间间隙、象素之间的已知响应差别。只要修正小,亦即各为百分之几,则它们将接近线性地加入,因此,各个修正在其被用于SLM之前能够简单地被加入。总和被象素中所需曝光剂量的数值放大。
其它照明源
根据激光器的波长和类型,准分子激光器具有500-1000Hz的受到限制的脉冲重复频率(prf)。这提供了具有沿x和y的缝合边沿的大场。在二个其它的最佳实施例中,用prf高得多的脉冲激光器,例如Q转换升频固体激光器,以及用SLM表面上扫描的连续激光源,来照明SLM,致使SLM的一部分被重新装载新数据,而另一部分被印制。在二种情况下,激光器的相干性质都不同于准分子激光器,并需要更大范围的光束编码和相干控制,例如具有不同路径长度的多个平行光路。在本发明的某些装置中,来自闪烁灯的光输出是足够的,并能够被用作光源。其优点是成本低而相干性质好。
在具有扫描照明的最佳实施例中,解决了二个问题:由于扫描是在最好使用诸如声光或电光之类的电光扫描仪进行完全控制的情况下进行的,且许多连续激光器具有比脉冲激光器更小的功率起伏,故解决了脉冲之间的时间和能量变化问题。而且,连续激光器的采用提供了波长的不同选择,且连续激光器比脉冲激光器对眼睛更不危险。但最重要的是,由于扫描是非临界的并能以100kHz或更高的重复速率进行,故利用仅仅具有几条线的矩阵,就可能达到高得多的数据速率。对照明光束进行扫描也是产生非常均匀的照明的一种方法,其它方法难以做到。
在某些实施例中,使用闪烁灯作为照明源是可能和可行的。
EUV
EUV光源基于来自粒子加速器、磁等离子体压缩机或以大功率激光脉冲将小滴物质加热到极高温度的辐射。在每种情况下,辐射都被脉冲化。EUV辐射仅仅在真空中传播,且仅仅能够被反射透镜聚焦。采用SLM的典型图形发生器具有中等光功率要求的小的曝光场。光学***的设计因而比EUV步进机更容易,使得有可能比步进机使用更多的反射镜并达到更高的NA。可以预料,高NA透镜将具有环形曝光场,并完全有可能使SLM的形状适应这种场。利用13nm的波长和0.25的NA,有可能对宽度仅仅为25nm的线进行曝光,而使用下面所述的图象增强方法,甚至有可能对小于20nm的线进行曝光。没有其它已知的写入技术能够比得上这一分辨率同时SLM的并行特性使这一写入速度成为可能。
边沿覆盖
由于对于各个闪烁印制二维场且各个场被边到边缝合在一起,故缝合是非常关键的。一个场的仅仅几毫微米的偏离就将沿此边沿产生明显的对掩模产生的电子电路的功能有潜在危害的图形误差。减轻这种不希望有的缝合效应的一种有效的方法是,几次印制同一个图形,但各次之间缝合边界有位移。若图形被印制4次,则缝合误差将出现在4个位置中,但大小仅仅为四分之一。在本发明的最佳实施例中,产生中间曝光的能力与场之间的覆盖带一起被应用。虽然在被压缩的数据的扩展过程中也能够进行,但在扫描过程中对数据进行计算。边沿覆盖降低了缝合误差,其产率代价比多次印制小得多。
改进的照明
在第一最佳实施例中,SLM的照明是用准分子激光器和诸如用来产生从照明器光孔平面中的环形自发光表面照明此装置的复眼透镜之类的光编码器来进行的。为了提高用特定投影***印制时的分辨率,有可能使用一种改进的照明。在最简单的情况下,光孔滤波器被引入到例如具有四极形或圆形发射区的照明器的光孔平面中。在更复杂的情况下,同一个场被印制几次。能够使诸如图象平面中的焦点、照明图形、加于SLM的数据、以及投影透镜光孔平面中的光孔滤波器之类的几个参数,在各次曝光之间发生改变。确切地说,照明与光孔滤波器的同步改变能够提供更高的分辨率,若光孔具有扇形发射区且照明被对准,致使非衍射光与扇形顶点附近的吸收斑相交,则最显著。
响应的线性化
对于从数据到边沿位置的传送函数的线性化,此处主要有三种方法:
-考虑数据转换单元中的非线性,并在数据转换单元中产生一个8位(例如)象素数值,且用具有相同分辨率的DAC驱动SLM。图8a示意地示出了这一点,其中R是中继信号,C是制作在SLM上各个矩阵元件上的电容器。用虚线表示SLM。
-产生具有例如5位的更少数值的或直到32个数值的数字数值,并将它们转换成查寻表(LUT)中的8位数值,然后将此8位数值馈送到DAC。
-用5位数值和半导体开关来选择由一个或几个高分辨率DAC产生的DC电压。图8b示意地示出了这一点。
在每一种情况下,都有可能测量实验校正函数,使当所述函数被加于各个数据转换单元、LUT或DC电压中时,平板上的响应被线性化。
使用哪一种线性化方案,取决于数据速率、精确度要求,还取决于能够得到的可能随时间变化的电路工艺。目前,数据转换单元是一瓶颈,因此,对数据转换单元进行线性化,或产生8位象素数值,都不是好的解决办法。高速DAC很昂贵且消耗功率,因而,最适当的解决办法是产生DC电压和使用开关。则有可能使用比8位更高的分辨率。
最佳图形发生器的描述
参照图6,图形发生器包含具有单个和多值象素寻址的SLM 601、照明源602、照明光束编码器件603、成像光学***604、具有干涉计位置控制***606的精细定位基底平台605、以及SLM的硬件和软件数据处理***607。为了恰当的功能和易于操作,还包含具有温度控制的周围人工气候室、基底装载***、用来对平台运动计时和曝光激光器触发以达到最佳图形位置精度的软件、以及软件用户界面。
图形发生器中的照明,用KrF准分子激光器进行,它提供长度为10-20ns的带宽对应于准分子激光器自然线宽的248毫微米波长UV区的光闪烁。为了避免基底上的图形畸变,来自准分子激光器的光被均匀地分布在SLM表面上,且此光具有足够短的相干长度,以便不在基底上产生激光斑点。光束编码器被用来达到这二个目的。它将来自准分子激光器的光束***到具有不同路径长度的几个光束路径中,然后将它们加在一起以便降低空间相干长度。光束编码器还具有由包含一组复眼透镜的透镜***组成的光束均衡器,它使来自准分子激光器的激光束中的各个点的光均匀地分布在SLM表面上,提供一种“顶帽”光分布。这种光束编码、均衡和相干降低,在所有SLM印相机中是有优点的。根据实际环境,能够采用使用光束***器和组合器、衍射元件、光纤、万花筒、小透镜阵列、棱镜或棱镜阵列或集成球的装置,以及***和组合光束以产生多个冲击到SLM上的相互不相干的光场的组合中的其它相似的器件。
来自SLM的光被中继并成像到基底平台上的基底上。用Kück描述的Schlieren光学***做到了这一点。焦宽为f1的透镜l1被置于离SLM的距离为f1处。焦宽为f2的另一透镜l2被置于离SLM的距离为2×f1+f2处。基底则在离SLM的距离为2×f1+2×f2处。在离SLM的距离为2×f1处有光圈608,其尺寸决定了***的数值孔径(NA),从而决定了能够在基底上写入的最小图形尺寸。为了修正光学***和基底平坦度的缺陷,还有聚焦***,它以50微米的位置间距沿z方向将透镜l2动态定位,以便达到最佳聚焦性质。透镜***还对248nm的照明波长进行波长修正,并具有至少±1nm的照明光的带宽容差。用位于透镜l1紧邻上方的光束***器609,将照明光反射到成像光学***中。对于250的缩小倍数和0.62的NA,有可能以良好的图形质量曝光尺寸小到0.2微米的图形。对于各个SLM象素的32个等级,最小网格尺寸为2nm。
图形发生器具有带干涉计位置控制***的精细定位基底平台。它由最小热膨胀的微晶玻璃制成的可运动的空气轴承xy平台605组成。具有干涉计位置反馈测量***606的伺服***,控制着平台沿各个方向的定位。沿方向y,伺服***保持平台在固定的位置,而沿另一个方向x,平台以连续的速度运动。干涉计位置测量***沿x方向被使用,以便触发曝光激光器闪烁,在基底上的SLM的各个图象之间提供均匀的位置。当SLM图象的整个行被曝光在基底上时,平台沿x方向移动回到原来位置,并沿y方向移动一个SLM图象增量,以便在基底上曝光另一行SLM图象。这一步骤被重复,直到整个基底被曝光。
SLM图象与大量象素沿x和y方向重叠,且覆盖象素中的曝光数据图形被局部修正以便补偿导致覆盖区域的增大的曝光数目。
利用图形的二次曝光来补偿来自准分子激光器的脉冲之间的强度变化,其中第一次曝光用正确强度标称90%的强度进行。在第一次曝光中,各个激光闪烁中的实际强度被测量并存储。在第二曝光中,根据从第一曝光测量得到的强度数值而使用各个SLM图象曝光的正确强度。以这种方法,有可能将来自准分子激光器的脉冲之间强度变化的影响降低一个数量级。
本文广泛地描述了SLM的功能。它具有尺寸为16微米的2048×256个象素,并有可能在1毫秒之内寻址所有的象素。SLM被稳固地安装在精细平台中。此精细平台能够沿x和y方向移动100微米,各个闪烁曝光之间的精度高于100nm。SLM的精细定位被用来修正基底定位平台的位置不准确性,以便进一步减小图形缝合误差。除了x-y定位之外,还有可能旋转SLM平台,以便在成角度的基底上而不是在基底平台坐标***规定的基底上曝光图形。这种旋转的目的是产生将基底对准可行性与要增加额外的图形的已有图形进行组合的可能性。利用偏轴光学通道和/或监视透镜的CCD摄象机,以便确定存在于基底上的大量对准记号的***坐标,有可能测量装载之后基底在平台上的准确位置。然后在曝光过程中,根据测量得到的对准记号的位置,沿x方向和y方向修正平台位置。利用平台伺服***跟随被旋转的坐标***并如所述旋转SLM精细平台,来获得旋转对准。旋转SLM的可能性还使得有可能在被畸变了的坐标***中写入,例如补偿随后的图形弯曲。
任意格式的任意数据图形被转换到压缩的扫描象素图中,图形扫描仪610中每个象素有32(5位)个灰度等级。由于被曝光的象素的灰度等级对施加在象素电极的电压不是线性的,故输入数据在象素线性化器611中被线性化,以便32个灰度等级对应于各个依次等级的曝光剂量的均匀增加。用8位数模转换器(DAC)612做到了这一点,其中象素图中的各个灰度等级,根据前面实验校正的线性化函数,从DAC选择电压。用其中各个数值对应于SLM象素且各个这样的数值修正对应象素的反常的查寻表,得到从DAC的模拟等级选择的额外偏离。用其中一系列测试图形被送到SLM,且得到的曝光图形被测量并用于各个象素修正的实验校正步骤,来产生查寻表中的校正数值。这意味着象素图中的各个灰度等级选择一个为每个对应SLM象素产生象素形变的模拟电压,以便提供正确的曝光剂量。
参考文献
Nelson 1988:US patent US 5148157
Kück 1990:European patent EP 0610183
Sandstrom et al.1990:European patent EP 0467076
Claims (44)
1.一种用在光投影***中的空间强度光调制方法,包括:
提供独立可寻址的反射镜元件的规则网格,所述反射镜元件具有旋转动作,其中网格中的反射镜元件被排列成使得第一反射镜元件具有旋转动作基本上不同的相邻的第二反射镜元件;
驱动反射镜元件以形成图形;以及
将来自反射镜元件的辐射投射到像平面上以再现该图形。
2.根据权利要求1的方法,其中所述网格是Cartesian网格。
3.根据权利要求1的方法,其中所述反射镜元件通过施加模拟电压而变形。
4.根据权利要求1的方法,其中所述网格具有多行的象素,并且一行中的反射镜元件按相同方向旋转,并且其中相邻行中的反射镜元件按相反的方向旋转。
5.根据权利要求1的方法,其中所述网格由相同的四象素组组成,其中每一个组具有在四个不同方向旋转的象素,并且每一组中在各方向上的矢量和为零。
6.根据权利要求1的方法,其中所述象素由相同的反射镜元件组组成,其中一组具有含四个不同旋转动作的反射镜元件,并且用于同等地驱动该组中的反射镜元件的方向矢量的矢量和基本上为零。
7.根据权利要求1的方法,其中所述反射镜网格在集成电路的顶部形成。
8.权利要求1的方法,其中所述投射步骤包括在被所述网格的反射镜元件反射之后,辐射穿过用于对辐射进行Fourier滤波的光学***。
9.一种用在从反射镜元件将辐射投射到像平面上以再现图形的光学投影***中的空间强度光调制器,包括:
独立可寻址反射镜的规则网格,所述反射镜元件具有旋转动作,其中网格中的反射镜元件被排列成使得第一反射镜元件具有旋转动作基本上不同的相邻的第二反射镜元件。
10.根据权利要求9的装置,其中所述网格是Cartesian网格。
11.根据权利要求9的装置,还包括连接到可寻址反射镜元件的模拟电压源,以驱动反射镜单元。
12.根据权利要求9的装置,其中所述网格由相同的四象素组组成,其中每一个组具有在四个不同方向旋转的象素,并且每一组中在各方向上的矢量和为零。
13.根据权利要求9的装置,其中所述网格由相同的反射镜元件组组成,其中一组具有含四个不同旋转动作的反射镜元件,并且用于同等地驱动该组中的反射镜元件的方向矢量的矢量和基本上为零。
14.一种用在光学投影***中的空间强度光调制方法,包括以下步骤:
提供独立可寻址的反射镜元件的规则网格,所述反射镜元件具有旋转动作,其中网格中的反射镜元件被排列成使得对于一组同等地驱动的相邻反射镜元件方向矢量的矢量和基本上为零;
驱动反射镜元件以形成图形;以及
将来自反射镜元件的辐射投射到像平面上以再现该图形。
15.根据权利要求14的方法,其中所述网格是Cartesian网格。
16.根据权利要求14的方法,其中所述反射镜元件通过施加模拟电压而变形。
17.根据权利要求14的方法,其中所述组具有2乘2象素的尺寸。
18.根据权利要求14的方法,其中所述网格具有多行的象素,并且一行中的反射镜元件按相同方向旋转,并且其中相邻行中的反射镜元件按相反的方向旋转。
19.根据权利要求14的方法,其中所述网格由相同的四象素组组成,其中每一个组具有按四个不同方向倾斜的象素,并且在每一组中各方向上的矢量和为零。
20.根据权利要求14的方法,其中所述网格由相同的四象素组组成,其中每一个组具有在四个不同方向旋转的象素,并且每一组中在各方向上的矢量和为零。
21.根据权利要求14的方法,其中所述反射镜网格在集成电路的顶部形成。
22.根据权利要求14的方法,其中所述投射步骤包括在被所述网格的反射镜元件反射之后,辐射穿过用于对辐射进行Fourier滤波的光学***。
23.根据权利要求14的方法,其中所述组包括三个最近邻的反射镜元件。
24.一种用在从反射镜元件将辐射投射到像平面上以再现图形的光学投影***中的空间强度光调制器,包括:
独立可寻址反射镜的规则网格,所述反射镜元件具有旋转动作,其中网格中的反射镜元件被排列成使得对于一组同等地驱动的相邻反射镜元件方向矢量的矢量和基本上为零。
25.一种用在光投影***中的空间强度光调制方法,包括:
提供独立地可寻址的反射镜元件的网格,所述反射镜元件具有旋转动作,其中网格中的反射镜元件被排列成使得:
第一反射镜元件具有旋转动作基本上不同的相邻的第二反射镜元件;以及
对于一组同等地驱动的相邻反射镜元件,方向矢量的矢量和为零;
驱动反射镜元件以形成图形;以及
从反射镜元件将辐射投射到像平面上以再现图形。
26.根据权利要求25的方法,其中所述网格是Cartesian网格。
27.根据权利要求25的方法,其中所述反射镜元件通过施加模拟电压而变形。
28.根据权利要求25的方法,其中所述组具有2乘2的尺寸。
29.根据权利要求25的方法,其中所述网格具有多行的象素,并且一行中的反射镜元件按相同方向旋转,并且其中在相邻行中的反射镜元件按相反的方向旋转。
30.根据权利要求25的方法,其中所述网格由相同的四象素组组成,其中每一个组具有按四个不同方向倾斜的象素,并且在每一组中各方向上的矢量和为零。
31.根据权利要求25的方法,其中所述网格由相同的四象素组组成,其中每一个组具有在四个不同方向旋转的象素,并且每一组中在各方向上的矢量和为零。
32.根据权利要求25的方法,其中所述反射镜网格在集成电路的顶部形成。
33.根据权利要求25的方法,其中所述投射步骤包括在被所述网格的反射镜元件反射之后,辐射穿过用于对辐射进行Fourier滤波的光学***。
34.根据权利要求25的方法,其中所述组包括三个最近邻的反射镜元件。
35.一种用在从反射镜元件将辐射投射到像平面上以再现图形的光学投影***中的空间强度光调制器,包括:
独立可寻址反射镜的规则网格,所述反射镜元件具有旋转动作,其中网格中的反射镜元件被排列成使得:
第一反射镜元件具有旋转动作基本上不同的相邻的第二反射镜元件;以及
对于一组同等地驱动的相邻反射镜元件,方向矢量的矢量和为零。
36.一种用于在对曝光辐射敏感的工件上产生图形的设备,如光掩模、显示器面板或微光学器件,包括:
曝光辐射源;
适于由所述辐射照射、具有多个调制元件/象素的空间光调制器;
将所述辐射从调制器投射到工件上的投影***;
空间光调制器的调制元件被驱动成在由空间光调制器的相邻调制元件调制的辐射各部分之间导致可控的相位差。
37.根据权利要求36的设备,其中所述可控的相位差在对应于调制元件的工件上的各区域之间产生附加的衬度。
38.根据权利要求36的设备,其中所述可控的相位差受相对于曝光辐射的波长具有0和+/-90度的相位的调制元件的影响。
39.根据权利要求36的设备,其中所述可控的相位差受相对于曝光辐射的波长具有90度相位差的调制元件的影响。
40.根据权利要求36的设备,其中所述空间光调制器是相位型空间光调制器。
41.根据权利要求36的设备,其中所述空间光调制器是偏转型空间光调制器。
42.一种用于在对曝光辐射敏感的工件上产生图形的设备,如光掩模、显示器面板或微光学器件,包括:
曝光辐射源;
适于由所述辐射照射、具有多个调制元件/象素的空间光调制器;
将所述辐射从调制器投射到工件的对应区域的投影***;
空间光调制器的调制元件被驱动成在到达对应于空间光调制器的相邻调制元件的工件的相邻区域的辐射之间导致可控的相位差。
43.根据权利要求42的设备,其中所述空间光调制器是相位型空间光调制器。
44.根据权利要求42的设备,其中所述空间光调制器是偏转型空间光调制器。
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