Projection exposure apparatus comprising a manipulator, and method for controlling a projection exposure apparatus

Patent metadata

Field	Value
Publication number	US-9760019-B2
Application number	US-201615002564-A
Country	US
Kind code	B2
Filing date	Jan 21, 2016
Priority date	Jan 22, 2015
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

A method for controlling a microlithographic projection exposure apparatus includes: determining a wavefront error of the projection exposure apparatus; generating a travel vector, suitable for correcting the wavefront error, with travels for each zone of the optical manipulator; establishing a constraint parameter with respect to the travel for at least one zone of the optical manipulator; and checking the travels of the generated travel vector with respect to implementability.

First claim

What is claimed is:

1. A method of controlling a microlithographic projection exposure apparatus which comprises a projection lens and an optical manipulator arranged in a beam path of the projection lens, the optical manipulator having a multiplicity of zones distributed over a cross section of the beam path with an individually adjustable optical effect in the beam path, the method comprising:
on the basis of a determined wavefront error in an image field of the projection exposure apparatus, generating a travel vector suitable to correct the wavefront error, the travel vector comprising a travel for each zone of the optical manipulator via a travel-generating optimization algorithm;
establishing a constraint parameter with respect to the travel for at least one zone of the optical manipulator;
checking travels of the generated travel vector with respect to implementability taking into account the established constraint parameter; and
implementing the following when there is a constraint in the implementability:
obtaining a correction value vector with correction values for a plurality of the zones of the optical manipulator on the basis of the constraint parameter and the generated travel vector;
establishing a corrected travel vector by correcting the travels of the generated travel vector on the basis of the corresponding correction values of the correction value vector; and
adjusting the optical effect of all zones of the optical manipulator with the aid of the corrected travel vector to compensate the wavefront error.

2. The method of claim 1 , wherein the constraint parameter prescribes a maximum admissible travel for the at least one zone of the optical manipulator.

3. The method of claim 1 , further comprising testing an actuator characteristic of the zones of the optical manipulator with respect to observing a target specification for a travel range and fixing the constraint parameter at a maximum admissible travel for a faulty zone with an actuator characteristic deviating from the target specification.

4. The method of claim 1 , wherein:
the optical manipulator comprises a deformable mirror;
the zones are respectively deformable regions of a reflecting coating of the deformable mirror; and
the optical effect for each zone of the deformable mirror is adjusted by a deformation in accordance with the travels of the corrected travel vector.

5. The method of claim 1 , wherein:
the optical manipulator comprises an irradiation device and an optical element arranged in the beam path of the projection lens; and
the method comprises using the irradiation device to separately irradiate zones on the optical element with radiation at a wavelength that from an exposure wavelength of the projection exposure apparatus to obtain the optical effect to compensate the wavefront error via heating of the zones.

6. The method of claim 1 , wherein:
for each zone, the optical effect of each zones is adjustable via a respective control signal; and
the method further comprises testing for erroneous synchronization of the control signals of two zones; and
the constraint parameter prescribes a uniform travel for the two affected zones if an erroneous synchronization is present.

7. The method of claim 6 , wherein:
the optical manipulator comprises a deformable mirror configured so that the optical effect of the zones is individually adjustable via control electrodes contacting a piezoelectric layer; and
the erroneous synchronization of the control signals of two zones is performed by a short circuit of two adjacent control electrodes.

8. The method of claim 6 , wherein:
the optical manipulator comprises a current-operated thermal manipulator configured so that the control signals for adjusting the optical effect of the zones are generated by individual electrical heating of the zones;
testing for an erroneous synchronization of the control signals of two zones comprises testing for an electrical short circuit in heating of two adjacent zones;
the electrical short circuit causes both zones to be heated to the same extent; and
the constraint parameter prescribes a uniform travel for the two adjacent zones when a short circuit is present.

9. The method of claim 1 , wherein obtaining the correction value vector comprises selecting a correction value vector from a multiplicity of correction value vectors provided for the projection exposure apparatus in a memory.

10. The method of claim 1 , wherein obtaining the correction value vector comprises:
establishing a base correction vector with base travels on the basis of the constraint parameter;
establishing a scaling factor on the basis of the generated travel vector and the established base correction vector; and
calculating the correction value vector by scaling the base correction vector with the established scaling factor.

11. The method of claim 10 , wherein establishing the base correction vector comprises selecting of a base correction vector from a multiplicity of base correction vectors provided for the projection exposure apparatus in a memory.

12. The method of claim 10 , wherein, when a faulty zone of the optical manipulator with a travel range deviating from a target specification is present, establishing the base correction vector comprises:
determining a maximum correction travel for the faulty zone on the basis of the target specification and an actual travel range;
determining maximum travel ranges for all other zones of the manipulator; and
solving an optimization problem with the maximum correction travel of the faulty zone, the maximum travel ranges of all other zones and a minimum or predetermined aberration as constraints for determining the base travels of the base correction vector.

13. The method of claim 12 , wherein:
testing an actuator characteristic of the zones of the optical manipulator to establish a presence of a faulty zone and, when a faulty zone is present, calculating a base correction vector are carried out during the production of the optical manipulator; and
the optical manipulator is provided for the projection exposure apparatus together with the calculated base correction vector.

14. The method of claim 12 , wherein establishing the scaling factor when a faulty zone of the optical manipulator with a travel range deviating from a target specification is present is based on an exceedance value of the travel range by the generated travel and a nominal design of the base correction vector established for the faulty zone.

15. The method of claim 10 , wherein:
the respective optical effect of the zones is adjustable by respective control signals; and
establishing the base correction vector comprises calculating a base correction vector for two zones of the manipulator, the control signals of which are synchronized, by solving an optimization problem with a predetermined difference between different travels for the two zones, maximum travel ranges for all other zones of the optical manipulator and minimum aberration as constraints to determine the base travels of the base correction vector.

16. The method of claim 15 , wherein:
the optical manipulator comprises a deformable mirror configured so that the optical effect of the zones is individually adjustable via control electrodes contacting a piezoelectric layer, or the optical manipulator comprises a current-operated thermal manipulator configured so that the optical effect of the zones is individually adjustable by electrical heating; and
calculating the base correction vector is performed for two adjacent, electrically short-circuited z

Assignees

• Zeiss Carl Smt Gmbh

Inventors

• Bittner Boris
• Walter Holger

Classifications

• G03F7/70191

  Optical correction elements, filters or phase plates for controlling intensity, wavelength, polarisation, phase or the like · CPC title

• G03F7/706

  Aberration measurement · CPC title

• G03F7/70266 Primary

  Adaptive optics, e.g. deformable optical elements for wavefront control, e.g. for aberration adjustment or correction · CPC title

• G03F7/70616 Primary

  Monitoring the printed patterns · CPC title

• G03F7/70308

  Optical correction elements, filters or phase plates for manipulating imaging light, e.g. intensity, wavelength, polarisation, phase or image shift · CPC title