The invention relates to a method for determining a beamlet position in a charged particle multi-beamlet exposure apparatus. The apparatus is provided with a sensor comprising a conversion clement for converting charged particle energy into light and a light sensitive detector. The conversion element is provided with a sensor surface area provided with a 2D-pattern of beamlet blocking and non-blocking regions. The method comprises taking a plurality of measurements and determining the position of the beamlet with respect to the 2D-pattern on the basis of a 2D-image created by means of the measurements. Each measurement comprises exposing a feature onto a portion of the 2D-pattern with a beamlet, wherein the feature position differs for each measurement, receiving light transmitted through the non-blocking regions, converting the received light into a light intensity value, and assigning the light intensity value to the position at which the measurement was taken.
|
0. 18. A method for determining a beamlet position of a charged particle beamlet in a charged particle multi-beamlet exposure apparatus provided with a sensor comprising a detector and a sensor surface area provided with a two-dimensional pattern of beamlet blocking and non-blocking regions, the method comprising:
taking a plurality of measurements corresponding to different positions to form a two-dimensional grid, wherein each measurement comprises:
exposing a two-dimensional feature at a position onto the two-dimensional pattern with a charged particle beamlet, wherein the position at which the two-dimensional feature is exposed differs for each measurement;
receiving charged particles, being part of the charged particle beamlet exposing the two-dimensional feature, being transmitted through the non-blocking regions of the two-dimensional pattern; and
converting received charged particles into an intensity value using the detector, wherein the intensity value is assigned to the position at which the measurement was taken; and
determining a location of the charged particle beamlet with respect to the two-dimensional pattern on the basis of a two-dimensional image created using intensity values at the different positions within the two-dimensional grid.
1. A method for determining a beamlet position of a charged particle beamlet in a charged particle multi-beamlet exposure apparatus provided with a sensor comprising a conversion element for converting the energy of charged particles into light and a light sensitive detector, the conversion element being provided with a sensor surface area provided with a two-dimensional pattern of beamlet blocking and non-blocking regions, the method comprising:
taking a plurality of measurements using said charged particle beamlet, wherein said charged particle beamlet is turned off or blocked from reaching the two-dimensional pattern in between each of said plurality of measurements,
wherein each measurement comprises:
writing two-dimensional feature at a position onto a portion of the two-dimensional pattern with said charged particle beamlet, wherein said two-dimensional feature is written by scanning the charged particle beamlet along a two-dimensional path over the two-dimensional pattern while allowing the charged particle beamlet to expose the two-dimensional pattern during a portion of the two-dimensional path wherein the position at which the feature is exposed differs for each measurement, the positions forming a two-dimensional grid;
receiving light generated by the conversion element in response to charged particles, being part of said charged particle beam writing the two-dimensional feature, being transmitted through the non-blocking regions of the two-dimensional pattern; and
converting the received light into a light intensity value by means of the light sensitive detector, and assigning the light intensity value to the position at which the measurement was taken;
wherein the position at which the two-dimensional feature is written onto the portion of the two-dimensional pattern differs for each measurement, resulting in a plurality of two-dimensional features being written onto the two-dimensional pattern, the positions at which the two-dimensional features are written forming a two-dimensional grid;
determining the position of said charged particle beamlet with respect to the two-dimensional pattern on the basis of a two-dimensional image created by means of the light intensity values at the different positions within the two-dimensional grid, the two-dimensional image showing light intensity as a function of grid position.
13. A method for determining a distance between two beamlets in a charged particle multi-beamlet exposure apparatus provided with a sensor comprising a conversion element for converting the energy of charged particles into light and a light sensitive detector, the conversion element being provided with a sensor surface area provided with a two-dimensional pattern of beamlet blocking and non-blocking regions, the method comprising:
performing a method for determining a beamlet position of a charged particle beamlet in said charged particle multi-beamlet exposure apparatus, the method for determining a beamlet position comprising:
taking a plurality of measurements using said charged particle beam let, wherein each measurement comprises:
exposing a two-dimensional feature at a position onto a portion of the two-dimensional pattern with said charged particle beamlet wherein the position at which the feature is exposed differs for each measurement, the positions forming a two-dimensional grid;
receiving light generated by the conversion element in response to charged particles, being part of said charged particle beam writing the two-dimensional feature, being transmitted through the non-blocking regions of the two-dimensional pattern; and
converting the received light into a light intensity value by means of the light sensitive detector, and assigning the light intensity value to the position at which the measurement was taken;
determining the position of said charged particle beamlet with respect to the two-dimensional pattern on the basis of a two-dimensional image created by means of the light intensity values at the different positions within the two-dimensional grid;
transferring the two-dimensional pattern in a direction substantially parallel to the sensor surface plane over a predetermined distance;
taking a plurality of said measurements for determining a beamlet position of a charged particle beamlet in said charged particle multi-beamlet exposure apparatus,
wherein each measurement comprises:
exposing a two-dimensional feature onto a portion of the two-dimensional pattern with a further charged particle beamlet, the further charged particle beamlet having a theoretical distance from said charged particle beamlet equal to the predetermined distance over which the two-dimensional pattern has been transferred, wherein the position at which the feature is exposed differs for each measurement, the positions forming a two-dimensional grid;
receiving light generated by the conversion element in response to charged particles, being part of said charged particle beam writing the two-dimensional feature, being transmitted through the non-blocking regions of two-dimensional pattern; and
converting the received light into a further light intensity value by means of the light sensitive detector, and assigning the further light intensity value to the position at which the measurement was taken;
determining the position of the further charged particle beamlet with respect to the two-dimensional pattern on the basis of a two-dimensional image created by means of the further light intensity values at the different positions within the two-dimensional grid;
determining the actual distance between the charged particle beamlet and the further beamlet based on the determined charged particle beamlet position, the determined further charged particle beamlet position and the predetermined distance.
2. The method of
3. The method of
4. The method of
5. The method of
6. The method of
7. The method of
8. The method of
9. The method of
10. The method of
11. The method of
12. A computer readable medium for performing, when executed by a processor, the method for determining a beamlet position in a charged particle multi-beamlet exposure apparatus according to
14. The method of any
15. The method of
16. The method of
17. Computer readable medium for performing, when executed by a processor, the method for determining an actual distance between two beamlets in a charged particle multi-beamlet exposure apparatus according to
0. 19. The method of claim 18, further comprising:
transferring the two-dimensional pattern by a predetermined vector distance corresponding to a nominal distance between the charged particle beamlet and another charged particle beamlet in the charged particle multi-beamlet exposure apparatus;
determining a location of the another charged particle beamlet; and
determining a distance between the charged particle beamlet and the another charged particle beamlet based on the predetermined vector distance and the determined locations of the charged particle beamlet and the another charged particle beamlet.
0. 20. The method of claim 19, wherein the nominal distance corresponds to a pitch between two neighboring beamlet blocking regions or two neighboring beamlet non-blocking regions among the beamlet blocking and non-blocking regions.
|
For example, the most upper left arrangement depicts the feature 43 being exposed with its center in the grid cell 41 formed by the first row and the first column in the two-dimensional (7×7) grid. Similarly, the most bottom right arrangement depicts the feature 43 being exposed with its center in the grid cell 41 formed by the last row and the last column in the two-dimensional (7×7) grid. For simplicity, not all possible 49 arrangements are shown, but merely the arrangements in which the exposed feature positions correspond to grid cells 41 that are formed by the first, fourth or seventh row and the first, second, fifth or seventh column in the two-dimensional (7×7) grid.
The two-dimensional grid is projected over a portion of a two-dimensional pattern of beamlet blocking and non-blocking regions provided on a sensor surface area. The sensor comprises a conversion element for converting the energy of charged particles into light. Light generated by the conversion element is received in response to charged particles being transmitted through non-blocking regions within the two-dimensional pattern. The received light may be converted into a light intensity value using a light sensitive detector, such as a CCD-camera.
In each measurement, a light intensity value is derived by conversion of the received light. The light intensity value is then assigned to the grid cell 41 onto which the exposed feature was centered. Consequently, in this example 7×7=49 light intensity values may be obtained.
Taking measurements at different positions, for example to create the arrangements shown in
Another way of taking measurements at different positions is by using one or more electrostatic deflectors. By suitably deflecting the beamlet between measurements such that the beamlet is centered onto the desired grid cell for the next measurement to be taken, the two-dimensional image may be created.
Yet another way of taking measurement is making use of the writing scheme of the exposure apparatus. Typically, a writing scheme includes the movement of beamlets over a surface along a predetermined path. By modulating the beamlet (on or off) a pattern is written on the surface. Beamlet movement may include mechanical movement of the beam with respect to the target surface and/or deflection movement by one or more electrostatic deflectors. By scanning a beamlet along a two-dimensional path over the two-dimensional pattern, while allowing the beamlet to expose the two-dimensional pattern during a portion of the scan path a measurement may be taken. If such scanning is repeatably executed, while the scan path portion at which the two-dimensional pattern is exposed differs for each measurement, a sequence of measurement arrangements as shown in
Preferably, the apertures 52 are of the same size as the expected projection size of the beamlet 43 during exposure on the sensor surface. Such similar size increases the sensitivity of the measurement, because a small deviation from the perfect mutual alignment position already causes a distinguishable decrease of the detected light intensity value.
The plurality of measurements being taken on the two-dimensional pattern enables the creation of a two-dimensional image, showing light intensity as a function of grid position. A fitting algorithm may now be applied to the resulting two-dimensional image to obtain the actual position of the beamlet 43 with respect to the aperture 52 with sub-grid cell accuracy. Such fitting algorithm may include fitting of a two-dimensional (2D) Gauss onto the two-dimensional image. The inventors have realized that the convolution of a substantially circular aperture with the substantially circular beamlet projection on the sensor surface as a function of the extent of their mutual alignment closely resembles a 2D Gauss.
Embodiments of the invention have been described with reference to a single beamlet 43 and a two-dimensional pattern with a single feature, i.e. aperture 52. However, some embodiments of the invention may also be used to determine the beamlet position of a plurality of beamlets. In such case, the two-dimensional pattern may include a plurality of features such as apertures, each beamlet being measured with respect to a different feature.
Although
Furthermore, the parallel measurement of a plurality of beamlets 61 may result in the determination of a position of a subbeam of which the beamlets 61 are part. The use of multiple measurements in parallel increases the signal-to-noise ratio of the subbeam position measurement.
Theoretically, beamlets in a multiple beamlet exposure system are spaced apart in accordance with a known design. As a result, the nominal vector distance, for example defined as the x and y coordinates of a hypothetically perfect system, between separate beamlets within the design is known. This knowledge may be used to control stitching. However, due to practical limitations, the actual vector distance between beamlets is not identical to the nominal vector distance. As a result, so-called stitching errors may occur. A stitching error may be defined as the vector deviation between a nominal position and an actual position of a beamlet patterning a surface.
The measurement methods discussed above may further be used to determine an actual vector distance between a first beamlet and a second beamlet in the surface plane of the charged particle receiving surface of the conversion element. Furthermore, a deviation from a nominal vector distance between two beamlets may be derived. Determining the actual vector distance between two beamlets, or, additionally or alternatively, determining a deviation from a nominal vector distance between two beamlets, can be useful for predicting a stitching error resulting from exposing a target surface with a multi-beamlet exposure apparatus using the respective beamlets. If the actual vector distance is known, the control data can be amended by replacement of the nominal vector distance by the measured actual vector distance with respect to these beamlets. If the deviation from the nominal vector distance is known, adequate compensation can be arranged by amending the control data of at least one of the respective beamlets.
Embodiments of the method for determining an actual vector distance between a first beamlet and a second beamlet may include the following. First, a beamlet position of the first beamlet is determined using an embodiment of the abovementioned method for determining a beamlet position in a charged particle multi-beamlet exposure apparatus. Then, the two-dimensional pattern is transferred in a direction substantially parallel to the sensor surface plane over a predetermined vector distance. The predetermined vector distance is defined as a predetermined distance in a predetermined direction in the surface plane of the charged particle receiving surface of the sensor. The predetermined distance generally corresponds to the theoretical distance between the first beamlet and the second beamlet. Similarly, the predetermined direction generally corresponds to the direction at which, starting from the first beamlet, the second beamlet is to be expected.
Typically, transferring the two-dimensional pattern is the easiest way to arrange exposure of the two-dimensional pattern by the first beamlet and the second beamlet. However, it may also be feasible to transfer the second beamlet over a predetermined vector distance, or to allow relative movement between the beamlets and the two-dimensional pattern with respect to each other.
Then, a beamlet position of the second beamlet is determined using an embodiment of the abovementioned method for determining a beamlet position in a charged particle multi-beamlet exposure apparatus. So, a plurality of measurements is taken at different positions, where the measurement positions form a two dimensional grid, each measurement comprising exposing a portion of the two-dimensional pattern with the second beamlet, receiving light generated by the conversion element in response to charged particles being part of the second beamlet transmitted through the non-blocking regions of two-dimensional pattern, and converting the received light into a further light intensity value by means of the light sensitive detector. The position of the second beamlet is then determined with respect to the two-dimensional pattern on the basis of a further two-dimensional image created by means of the further light intensity values at the different positions within the two-dimensional grid.
Finally, the actual distance between the first beamlet and the second beamlet is determined on the basis of the determined beamlet position of the first beamlet, the determined beamlet position of the second beamlet and the predetermined vector distance.
Again, in addition to the determination of an actual distance between two beamlets, such determination may be performed for multiple beamlet pairs within a plurality of beamlets in parallel. Such parallel measurement would improve the signal-to-noise ratio of the measurements being performed.
The beamlet generator typically comprises a source and at least one beam splitter. The source in
In
The lithography system 80 of
The beamlet modulator typically comprises a beamlet blanker array 89 comprising an arrangement of a plurality of blankers. Typically, the beamlet blanker array 89 cooperates with a beamlet stop array 90. The blankers are capable of deflecting one or more of the electron beamlets 87. In embodiments of the invention, the blankers are more specifically electrostatic deflectors provided with a first electrode, a second electrode and an aperture. The electrodes are then located on opposing sides of the aperture for generating an electric field across the aperture. Generally, the second electrode is a ground electrode, i.e. an electrode connected to ground potential. To focus the electron beamlets 87 within the plane of the blanker array 89 the lithography system may further comprise a condenser lens array.
In the embodiment of
The beamlet modulator is arranged to add a pattern to the beamlets 87 on the basis of input provided by a control unit 100. The control unit 100 may be located remote from the rest of the system, for instance outside the inner part of a clean room. The control system 100 may further be connected to an actuator system 96. The actuator system is arranged for executing a relative movement of the electron-optical column, i.e. the components of the lithography system 80 for generating and projecting the beamlets represented by the dashed line 98 in
Modulated light beams 94 holding pattern data are transmitted to the beamlet blanker array 89 using optical fibers. More particularly, the modulated light beams 94 from optical fiber ends part of an optical fiber array 95 are projected, e.g. by using one or more lenses 97, on corresponding light sensitive elements located on the beamlet blanker array 89. The light sensitive elements may be arranged to convert the light signal into a different type of signal, for example an electric signal. A modulated light beam 94 carries a portion of the pattern data for controlling one or more blankers that are coupled to a corresponding light sensitive element. In some embodiments, the light beams 94 may, at least partially, be transferred towards the light sensitive elements by means of an optical waveguide.
The modulated beamlets coming out of the beamlet modulator are projected as a spot onto a target surface of a target 93 by the beamlet projector. The beamlet projector typically comprises a scanning deflector for scanning the modulated beamlets over the target surface and a projection lens system for focusing the modulated beamlets onto the target surface. These compounds may be present within a single end module.
Such end module is preferably constructed as an insertable, replaceable unit. The end module may thus comprise a deflector array 91, and a projection lens arrangement 92. The insertable, replaceable unit may also include the beamlet stop array 90 as discussed above. After leaving the end module, the beamlets 87 impinge on a target surface positioned at a target plane. For lithography applications, the target 93 usually comprises a wafer provided with a charged-particle sensitive layer or resist layer.
The deflector array 91 may take the form of a scanning deflector array arranged to deflect each beamlet 87 that passed the beamlet stop array 90. The deflector array 91 may comprise a plurality of electrostatic deflectors enabling the application of relatively small driving voltages. Although the deflector array 91 is drawn upstream of the projection lens arrangement 92, the deflector array 91 may also be positioned between the projection lens arrangement 92 and the target surface.
The projection lens arrangement 92 is arranged to focus the beamlets 87, before or after deflection by the deflector array 91. Preferably, the focusing results a geometric spot size of about 10 to 30 nanometers in diameter. In such preferred embodiment, the projection lens arrangement 92 is preferably arranged to provide a demagnification of about 100 to 500 times, most preferably as large as possible, e.g. in the range 300 to 500 times. In this preferred embodiment, the projection lens arrangement 92 may be advantageously located close to the target surface.
Commonly, the target surface comprises a resist film on top of a substrate. Portions of the resist film will be chemically modified by application of the beamlets of charged particles, i.e. electrons. As a result thereof, the irradiated portion of the film will be more or less soluble in a developer, resulting in a resist pattern on a wafer. The resist pattern on the wafer can subsequently be transferred to an underlying layer, i.e. by implementation, etching and/or deposition steps as known in the art of semiconductor manufacturing.
In the system shown in
A first possibility is to move the two-dimensional pattern in between measurements. In
A second option, which may be combined with the abovementioned displacement of the two-dimensional pattern, is the use of one or more electrostatic deflectors. Taking measurements at different positions may then be achieved by suitably deflecting the beamlet which position is to be determined in between measurements. Such electrostatic deflectors may already be present in the charged particle multi-beamlet exposure apparatus for other purposes, e.g. the one or more deflectors may be part of the deflector array 91 in the system 80 of
Yet another way to take the measurements at different positions for determining the beamlet position is to scan the beamlet along a two-dimensional path over the two dimensional pattern while allowing the beamlet to expose the two-dimensional pattern during a portion of the scan path. In order to form different portions in the two-dimensional grid, for each measurement the scan path portion at which the two-dimensional pattern is exposed differs.
The invention has been described by reference to certain embodiments discussed above. It will be recognized that these embodiments are susceptible to various modifications and alternative forms well known to those of skill in the art. Further modifications in addition to those described above may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, these are examples only and are not limiting upon the scope of the invention, which is defined in the accompanying claims.
Patent | Priority | Assignee | Title |
Patent | Priority | Assignee | Title |
6353231, | Aug 31 1998 | Nikon Corporation | Pinhole detector for electron intensity distribution |
6958804, | Oct 25 2002 | ASML NETHERLANDS B V | Lithography system |
7423274, | Mar 01 2005 | Hitachi High-Technologies Corporation; Canon Kabushiki Kaisha | Electron beam writing system and electron beam writing method |
7868300, | Sep 15 2005 | ASML NETHERLANDS B V | Lithography system, sensor and measuring method |
9030675, | Nov 13 2010 | ASML NETHERLANDS B V | Method for determining a distance between two beamlets in a multi-beamlet exposure apparatus |
20060197453, | |||
20070057204, | |||
20110253900, | |||
20120293810, | |||
EP1335249, | |||
JP1227087, | |||
JP2004111422, | |||
JP2005032508, | |||
JP2005347054, | |||
JP54068149, | |||
JP55070024, | |||
NLO2012062931, | |||
NLP1335249, | |||
WO2007032670, | |||
WO2012062931, |
Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Jun 21 2013 | SCHEFFERS, PAUL IJMERT | MAPPER LITHOGRAPHY IP B V | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 062628 | /0543 | |
Jan 03 2019 | MAPPER LITHOGRAPHY IP B V | WITTEKAMP, J J | COURT APPOINTMENT SEE DOCUMENT FOR DETAILS | 062683 | /0259 | |
Feb 06 2019 | WITTEKAMP, J J | ASML NETHERLANDS B V | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 062683 | /0181 | |
May 16 2019 | ASML Netherlands B.V. | (assignment on the face of the patent) | / |
Date | Maintenance Fee Events |
May 16 2019 | BIG: Entity status set to Undiscounted (note the period is included in the code). |
Nov 05 2024 | M1552: Payment of Maintenance Fee, 8th Year, Large Entity. |
Date | Maintenance Schedule |
Apr 04 2026 | 4 years fee payment window open |
Oct 04 2026 | 6 months grace period start (w surcharge) |
Apr 04 2027 | patent expiry (for year 4) |
Apr 04 2029 | 2 years to revive unintentionally abandoned end. (for year 4) |
Apr 04 2030 | 8 years fee payment window open |
Oct 04 2030 | 6 months grace period start (w surcharge) |
Apr 04 2031 | patent expiry (for year 8) |
Apr 04 2033 | 2 years to revive unintentionally abandoned end. (for year 8) |
Apr 04 2034 | 12 years fee payment window open |
Oct 04 2034 | 6 months grace period start (w surcharge) |
Apr 04 2035 | patent expiry (for year 12) |
Apr 04 2037 | 2 years to revive unintentionally abandoned end. (for year 12) |