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53
Tom Milster
Optical Sciences Center, University of Arizona, Tucson, Arizona 85721
Alan E. Rosenbluth
IBM T. J. Watson Research Center, P.O. Box 218, Yorktown Heights, New York 10598
Received May 23, 1994; accepted July 26, 1995; revised manuscript received July 28, 1995
A description is given of a modeling technique that is used to explore three-dimensional image distributions
formed by high numerical aperture sNA . 0.6d lenses in homogeneous, isotropic, linear, and source-free thin
films. The approach is based on a plane-wave decomposition in the exit pupil. Factors that are due to
polarization, aberration, object transmittance, propagation, and phase terms are associated with each planewave component. These are combined with a modified thin-film matrix technique in a derivation of the
total field amplitude at each point in the film by a coherent vector sum over all plane waves. One then
calculates the image distribution by squaring the electric-field amplitude. The model is used to show how
asymmetries present in the polarized image change with the influence of a thin film. Extensions of the model
to magneto-optic thin films are discussed. 1996 Optical Society of America
1.
INTRODUCTION
magnetic distribution within a medium has been examined extensively by Ling and Lee,9 based on methods by
Gasper et al.10 However, the description of high-NA volume imaging into layered media with the use of extended
objects, such as is the case in microlithography, is not
discussed at any length. It was not until Yeung that a
high-NA vector model for photoresist emerged.11 Yeung
based his imaging theory on the work of Richards and
Wolf 4 and used a numerical solution to derive the threedimensional (3-D) image as a weighted sum of plane
waves propagating into the photoresist. Yeung simplified his model by assuming that the object is a periodic
grating, thus reducing the problem to a two-dimensional
(2-D) solution for S or P polarization. He treated propagation into a bleaching photoresist as a one-dimensional
(1-D) electromagnetic grating problem, using differential
methods to calculate the fields. After realizing that the
bleaching effects do not substantially alter the image,
Yeung presented a further simplification12 by assuming
homogeneous and linear thin films. This allowed the use
of standard thin-film matrix techniques for calculation of
the electromagnetic fields within the photoresist. Yuan
derived a 1-D vector imaging model with a 2-D waveguide scattering model to simulate high-NA images that
can accommodate nonplanar substrates.13 However, like
Yeungs work, it is limited to polarization in either S or P
and cannot describe the more general 3-D imaging case.
The intent of this work is to present a model for vector
image formation within the volume of the first film of a
general thin-film stack.14 18 The primary film of interest is photoresist, but the theory is sufficiently general to
accommodate other applications. The films are considered to be homogeneous, isotropic, linear, and source free.
The model is based on the generalized Debye approach19
in which the vector image field is characterized as a plane 1996 Optical Society of America
54
2.
METHODOLOGY
Our model simulates a Kohler optical projection system with polarized coherent illumination. The projector
forms an image of the object in the vicinity of a thin-film
assembly, as shown in Fig. 1. The polarization just before the object is decomposed into components along the
x axis and the y axis. The imaging lens is assumed to
be lossless, with an image-side NA typically $ 0.6 but an
object-side NA , ,0.2. The imaging lens is represented
by an entrance pupil reference sphere whose center of
curvature is at the object and by an exit pupil reference
sphere whose center of curvature is at the geometrical
focus. Aberrations are defined by small deviations from
the exit pupil sphere in terms of wave-front phase errors.
The imaging is stationary (or shift invariant),21,22 which
implies that an x y translation of the object field results
in only a likewise translation of the image. This assumption results in isoplanatic conjugate fields, such that the
aberrations across the fields are constant. Isoplanatic
imaging imposes strong constraints on the image-forming
properties of the system, allowing one to model it without
considering in detail the propagation of light between the
entrance and exit pupil surfaces. Hopkins used this assumption to show that the entrance pupil must exist in
the Fraunhofer region of the object, whereas the image
exists in the Fraunhofer region of the exit pupil.
The propagation direction of a general plane wave
through the optical system is described by a geometrical
ray with a direction given by the propagation vector k, as
shown in Fig. 2. The polarization direction of the elec-
Flagello et al.
Flagello et al.
Fig. 3.
p
the NA must be large compared with lyr 0 , where r 0 is
the distance from the exit pupil to the image. In this
work a local field size less than 10 mm about the axis is
used,
with r 0 . 500 mm and l 0.442 mm.
p This gives
p
0
lyr , 0.03, which satisfies the condition lyr 0 , NA.
We calculate the E fields in the volume of the film by
summing forward and backward plane waves within the
film and satisfying boundary-value conditions at the interfaces. The E fields are derived through a modification
of the thin-film matrix technique outlined by Macleod,28
which defines additional reflection and transmission coefficients with respect to the interface between the first
film and the second film. Since the intent here is to calculate the total vector fields inside a film, the solution of
the axial szd electric-field component is required, in addition to the transverse components on which traditional
thin-film matrices operate. Finally, the image distribution within the first film of a thin-film stack is given by
Joules heat term, Q, defined by Poyntings theorem and
is proportional to jEj2 for an isotropic medium.
3. PRELIMINARY DEFINITIONS
AND NOTATIONS
A plane wave with a propagation vector k at a position
r is given by
U sx, y, zd U0 sx, y, zdexpsik ? rd
U0 sx, y, zdexpf2i2pNsax 1 by 1 gzdg , (1)
where
r l0 sxx 1 yy 1 zzd ,
!
ky
kz
2pN kx
x1
y 1
z
k
l0
k
k
k
2pN
fscos f sin udx 1 ssin f sin udy 1 scos udzg
l0
2pN
sax 1 by 1 gzd .
l0
(2)
55
1
2
sjEj2 k0 Y nkjEj2 ,
(3)
where s is the conductivity, Y is the free-space admittance, and k0 2pyl0 . If we assume that only Ohmic
losses are being considered, Q represents the form of the
recorded image distribution within an absorbing medium
with units of power per volume. It has been interpreted
by Stratton29 as the power dissipated by thermochemical
activity. In general, for photosensitive films, a fraction
of the energy absorbed is used in a photochemical reaction
with the remainder being dissipated as heat. Therefore
the recorded image within a film is proportional to jEj2 .
56
Flagello et al.
dS 0 r 02 dV 0 r 02
Fig. 5.
exps2i2prd
F hOsx, ydj ,
r
hNb h0 N 0 b 0 ,
(6)
h0
a
b
0 0.
h
a
b
(5)
r Esa,
bd ig exps2i2prdT sa, bdF hOsx, ydj ,
h ,
h
(4)
Esa,
bd Osa,
bdT sa, bd ,
3 expfi2psax 1 bydgdxdy
ig
and the primed notation is used to represent the imageside geometry, as shown in Fig. 6. r 0 has been written inside the transform for reasons that will be obvious shortly.
E 0 sa 0 , b 0 d is the scalar complex amplitude distribution in
the exit pupil. Note that the exponential term in z0 represents an image focus term. The geometrical focus, located at z0 0, is at the vertex of the solid angle subtended by the exit pupil.
A simple magnification scaling is assumed between entrance and exit pupils. Any aberrations within the lens
are treated with an aberration term that modifies the
phase of the wave front at the exit pupil reference surface. The transverse magnification is defined as
hNa h0 N 0 a 0 ,
exps2i2prd Z ` Z `
Osa,
bd ig
Osx, yd
r
2`
2`
da 0 db 0
g0
1
Osma 0 , mb 0 dT sma 0 , mb 0 d .
m2
The relationship between the magnitudes of the entrance pupil fields and the exit pupil fields must be taken
into account. Since there is a physical difference in size,
i.e.,
T 0 sa 0 , b 0 d T sma 0 , mb 0 d ,
(9)
and T 0 sa 0 , b 0 d is the exit pupil transmission function, conservation of energy must be ensured. Figure 7 illustrates
the differential areas on the entrance and exit pupil sur-
E 0 sx0 , y 0 ; z0 d
expsi2pr 0 d ZZ 0 0 0
E sa , b dexps2ik0 ? r0 ddS 0
2i
r0
S0
8
9
< 0 0 0 0
0 0 =
0
21 r E sa , b dexps2i2pg z d
, (7)
2i expsi2pr dF
:
;
g0
where an element of wave front dS 0 is defined by
(8)
Fig. 6.
Flagello et al.
57
Osa,
bd Osa,
bdMi ,
Fig. 7.
jEsa,
bdj2 da jE 0 sa 0 , b 0 dj2 da0 ,
where the differential areas on each pupil are given by
da r 2 dV r 2
dadb ,
g
da0 r 02 dV 0 r 02
Osa,
bd
Osa,
bd
Osa,
bdMi .
0
0
Similarly,
0
0
, mb 0 d Osma
, mb 0 dMi .
Osma
da db .
g0
p
r jE sa , b dj rjEsa, bdj
g da 0 db 0
s
g0 .
m
(10)
rjEsa,
bdj
g
As stated above, lens aberrations are given by a wavefront phase error W sa 0 , b d and are represented by a scalar
term, expf2i2pW sa 0 , b 0 dg. In the absence of any film
stack the scalar electric-field distribution, given by the
combination of Eqs. (7), (8), and (10), is
E 0 sx0 , y 0 ; z0 d
2i expsi2pr 0 d
8
9
<r 0 E 0 sa 0 , b 0 dexps2i2pg 0 z0 dexpf2i2pW sa 0 , b 0 dg=
3 F 21
:
;
g0
(
expsi2pr 0 d 21
0
2i
F
, mb 0 dexps2i2pg 0 z0 d
r Esma
m
)
1
0
0
3 expf2i2pW sa , b dg p 0 .
(11)
gg
Substitution of Eq. (6) and the application of Eq. (8) yield
E 0 sx0 , y 0 ; z0 d
where Osa,
bd and Mi are 2 3 1 matrices. Mi has elements given by Sl that may be complex, i.e.,
!
Sx .
Mi
Sy
expfi2psr 0 2 rdg
m
21
0 , b 0 ; z0 dj ,
3 F hOsma 0 , mb 0 dCsa
0 , b 0 ; z0 d,
ing the plane-wave amplitudes, Osma
, mb 0 dCsa
by the polarization amplitudes for each Cartesian component of the electric field. Figure 8 illustrates a propagation vector, k0 , with a direction sa 0 , b 0 d emerging from the
exit pupil. The polarization vector remains at a constant
orientation with respect to k0 and the meridional plane
defined by the plane of incidence with the film stack, and
the component amplitudes are projected onto the local S
or P coordinate system. The component amplitudes have
been defined by Mansuripur 8 in terms of the propagation
vector direction and the initial x or y polarizations from
P sa 0 , b 0 d
the object. It is given here as a 5 3 2 matrix M
with matrix elements Plmn , where l gives the initial object
polarization, m refers to the global sx, y, zd coordinates,
and n is the local S or P coordinate. Hence
3
2
2a 0 b 0
b 02
7
6
6 1 2 g 02 1 2 g 02 7
7
3 6
2
7
6 0 02
6 ga
PxxS PyxS
a0b0 g0 7
7
6
7 6
6
6PxxP PyxP 7 6 1 2 g 02 1 2 g 02 7
7
7 6
6
7
7
.
P sa 0 , b 0 d 6
6PxyS PyyS 7 6
2a 0 b 0
a 02 7
M
7
6
7 6
6
6PxyP PyyP 7 6 1 2 g 02 1 2 g 02 7
7
5 6
4
7
6 0 0 0
0 02 7
PxzP PyzP
gb
7
6abg
7
6
6 1 2 g 02 1 2 g 02 7
5
4
2a 0
2b 0
(14)
(12)
(13)
Fig. 8.
pupil.
58
Flagello et al.
the substitution
Fsz0 d 2pN1 g1 sd1 2 z0 1 z0 d
2psd1 2 z0 1 z0 dfN1 2 2 sin2 scos21 g 0 dg1/2
iI sa 0 , b 0 ; z0 d M
P sa 0 , b 0 dU
sa 0 , b 0 ; z0 d
A
0
P sa 0 , b 0 dOsma
, mb 0 dCsa 0, b 0 ; z0 d ,
M
(15)
iI is a 5 3 1 matrix with elements given by
where A
sAiI dmn . The distance z0 is an offset term that determines the initial phase for each plane wave incident on
interface I. Variation of z0 is equivalent to moving the
top film surface in and out of focus.
The derivation of the electric-field image amplitude
within the first layer of a thin-film stack is based on
the thin-film matrix techniques presented by Macleod.28
Figure 9 shows the geometry used for the calculation.
The vector field for any point within the first film is found
by summation of the downward and upward plane waves
for each S and P contribution, n, of the Cartesian component, m. The derivation presented here departs from the
typical thin-film method by deriving this field in terms
of the field at interface II, the bottom of the film, and
then relating the result to the incident field at interface I
through the matrix formalism. If the first film has a normalized thickness of d1 , the incident and reflected fields
at interface II are
A 1 sa1 , b1 d AiII expfi2pN1 g1 sd1 2 z0 1 z0 dg
(16)
(18)
3 expf2i2pN1 sa1 x0 1 b1 y 0 dg ,
(17)
A1 sa 0 , b 0 ; z0 d expf2i2psa0 x0 1 b 0 y 0 dg
3 fAiII exp iF 1 ArII exps2iFdg ,
(19)
b 0 Nj bj .
Fig. 9. Thin-film stack with incident plane waves and electricfield amplitudes.
Flagello et al.
Full Assembly
ArI
AiI
Atm
t
AiI
ArIz
rz
AiIz
Atmz
tz
AiIz
r
Transverse reflection
Transverse transmission
Axial reflection
Axial transmission
Subassembly
ArII
AiII
Atm
AiII
ArIIz
AiIIz
Atmz
AiIIz
rII
tII
rIIz
tIIz
Bh 0 2 C ,
Bh 0 1 C
Bs h1 2 Cs ,
rII
Bs h1 1 Cs
r
59
total vector electric image field within the film is calculated by the summation of all plane waves. Therefore
1 sa 0 , b 0 ; z0 dj
E1 sx0 , y 0 ; z0 d c0 F 21 hA
iI sa 0 , b 0 ; z0 dj
F sa 0 , b 0 ; z0 dA
c0 F 21 hM
F sa 0 , b 0 ; z0 dM
P sa 0 , b 0 d
c0 F 21 hM
0 , b 0 dCsa
0 , b 0 ; z0 dj .
3 Osa
(30)
(23)
x0 , y 0
Csx0 , y 0 ; z0 d .
O
m m
(24)
(31)
where h 0 is the incident admittance. The axial szd coefficients are not continuous across the boundaries. We derive them here by requiring that propagating plane waves
in the first film be solutions to Maxwells equations in
a source-free medium. In particular, the divergence of
the field must be 0 in the incident medium and the film;
hence, for a general plane wave,
= ? E k ? E 0.
rIIz
tII N1 g1
rIIz 2rII .
(25)
(26)
6.
(32)
GYRO-OPTIC MEDIA
a0
,
1 2 g 02
sin f p
b0
,
1 2 g 02
60
Flagello et al.
e
6
e 4iqe
0
2iqe
e
0
3
0
7
05.
e
(37)
where
"
0
0
0
M2
F sa , b ; z d exps2iFd
cos c
sin c
2 !
6 t rIIS
6 t
6 II S
36
6
4
0
2 sin c
cos c
0
!
trII
tII
#
3
7
7
7.
7
7
rIIP 5
(38)
Fig. 10. PSF for NA0 0.95 given by values of normalized jEj2 :
(a) isoimage contours, ( b) profiles along x and y.
Table 2.
Film Assembly
Optics
N0 1
N1 1.656 2 i0.004, d1 1 mm
Nm 1.656 2 i0.004
MSP is written as
2
MSP
b0
6p
6 1 2 g 02
6
6
4 p a0
1 2 g 02
Osx, yd dsx, yd
W 0, z0 0
2a 0
1 2 g 02
b0
p
1 2 g 02
p
3
7
7
7.
7
5
(34)
(35)
Flagello et al.
61
7.
(40)
RESULTS
Film Assembly
1
N1 1.656 2 i0.004, d1 1 mm
N0
Optics
NA0
0.95, l 0.442 mm
NA 0.048
W 0, z0 0, m 0.05
62
Flagello et al.
Figure 10 illustrates the effect of the film stack by comparing aerial PSF images (no film stack) to the PSF at
interface I of a thin-film stack, where jEj2 is normalized to
its maximum value. The parameters set for this example
are given in Table 2. The index of the first thin film represents a mildly absorbing photoresist. The substrate is
silicon. Clearly, interaction with the film reduces asymmetry in the PSF. This is caused by the reduction in the
cone angle of the transmitted beam through Snells law
as well as the angular dependence of reflectivity. The
image width decreases along the direction parallel to the
polarization and slightly increases along the perpendicular direction.
The image at interface I is further illustrated in Fig. 11,
where the PSF is shown for each xyz component and
the image, which is the component sum. The x component contains the most power and is similar to a scalar
response. The z component contains substantial power
that is distributed along the x axis. It is the primary
contributor to image asymmetry. The y component has
an interesting quadrupole symmetry but contains little
power and has an insignificant effect on the overall image. We further analyze PSF film images by considering
image contours in the film shown in Fig. 12(a) for meridional slices along the x and y axes. A slight image asymmetry exists along the film depth. Figure 12( b) shows
Fig. 16. Simulation of Q distribution of tribar object at interface I with NA0 0.95: Q distribution at top surface with x, y,
and z components.
Flagello et al.
63
8.
SUMMARY
This work presents a vector description of high-NA imaging in homogeneous thin films. The resultant derivation
gives a form for the image distribution within the volume of the first film of a thin-film stack. It is based on a
generalized Debye plane-wave decomposition of the radiation that propagates from the pupil. Each plane wave
is weighted by polarization, aberration, input amplitude,
and phase terms. We combine this decomposition with
a thin-film matrix technique to derive the electric fields
within the film.
The model is limited to imaging systems that have
isoplanatic object and image fields. In general, this requires that the optical system be well corrected, i.e., the
wave-front aberrations are below 0.25l. This requirement further implies that the electric-field polarization
is not substantially altered upon propagation through
the optical elements of the imaging lens. The polarization maintains a constant orientation with respect to the
propagation vector and the meridional plane.
We also present a vector formalism of image formation
as a linear, shift-invariant system. This gives rise to a
vector representation of transfer functions that are due to
the lens, the polarization, and the thin-film stack. We
further show a method to incorporate gyro-optic media
into the imaging.
Finally, examples were presented showing asymmetries
that are due to vector imaging components. The model
also accurately predicts classic spurious resolution as the
focal depth is increased.
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