JP4976094B2 - Illumination optical apparatus, exposure apparatus, exposure method, and microdevice manufacturing method - Google Patents

Description

  The present invention relates to an illumination optical apparatus, an exposure apparatus, an exposure method, and a microdevice manufacturing method, and is particularly used when a microdevice such as a semiconductor element, an image sensor, a liquid crystal display element, or a thin film magnetic head is manufactured in a lithography process. The present invention relates to an illumination optical apparatus suitable for an exposure apparatus.

  In a typical exposure apparatus of this type, a light beam emitted from a light source forms a secondary light source as a substantial surface light source including a large number of light sources via a fly-eye lens as an optical integrator. The light flux from the secondary light source (generally, the illumination pupil distribution formed in or near the illumination pupil of the illumination optical device) is limited through an aperture stop disposed in the vicinity of the rear focal plane of the fly-eye lens. After that, it enters the condenser lens.

  The light beam condensed by the condenser lens illuminates the mask on which a predetermined pattern is formed in a superimposed manner. The light transmitted through the mask pattern forms an image on the wafer via the projection optical system. Thus, the mask pattern is projected and exposed (transferred) onto the wafer. The pattern formed on the mask is highly integrated, and it is essential to obtain a uniform illuminance distribution on the wafer in order to accurately transfer this fine pattern onto the wafer.

  For example, in Japanese Patent No. 3246615 relating to the application of the present applicant, in order to realize an illumination condition suitable for faithfully transferring a fine pattern in an arbitrary direction, an annular zone is formed on the rear focal plane of the fly-eye lens. A technology for forming a secondary light source and setting the light beam passing through the annular secondary light source to be in a linear polarization state (hereinafter referred to as “circumferential polarization state” for short) with the circumferential direction as the polarization direction. Is disclosed.

Japanese Patent No. 3246615

  However, in the prior art disclosed in the above publication, the annular light source is limited by restricting the circular light beam formed through the fly-eye lens through an aperture stop having an annular opening. Forming. As a result, the prior art has a disadvantage in that a large light loss occurs in the aperture stop, which in turn reduces the throughput of the exposure apparatus.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to form a ring-shaped illumination pupil distribution in a circumferentially polarized state while favorably suppressing a light amount loss. In addition, the present invention forms a ring-shaped illumination pupil distribution in a circumferentially polarized state while suppressing loss of light quantity satisfactorily, so that a fine pattern in an arbitrary direction can be faithfully and high-throughput under appropriate illumination conditions. The purpose is to transfer.

In order to solve the above problems, in the first embodiment of the present invention, in the illumination optical device that illuminates the irradiated surface based on the light flux from the light source,
Polarization state switching means for switching the polarization state of incident light;
A light beam conversion element that is disposed in an optical path between the polarization state switching unit and the irradiated surface and that forms a light intensity distribution having a predetermined polarization characteristic on a predetermined surface based on an incident light beam;
The light beam conversion element is formed of an optical material having optical rotation, and forms a first polarization state in a first region distribution of the light intensity distribution having the predetermined polarization characteristic based on the incident light beam. The second polarization state is formed by the second region distribution of the light intensity distribution having the predetermined polarization characteristics based on the incident light flux. A second basic element for
The first basic element and the second basic element are different from each other in thickness along the light transmission direction.

  According to a second aspect of the present invention, there is provided an exposure apparatus comprising the illumination optical apparatus according to the first aspect for illuminating a mask, and exposing the pattern of the mask onto a photosensitive substrate.

  According to a third aspect of the present invention, there is provided an exposure method comprising: an illuminating step of illuminating a mask using the illumination optical apparatus according to the first aspect; and an exposing step of exposing a pattern of the mask onto a photosensitive substrate. I will provide a.

  According to a fourth aspect of the present invention, there is provided a microdevice comprising: an illuminating step of illuminating a mask using the illumination optical apparatus according to the first aspect; and an exposing step of exposing a pattern of the mask onto a photosensitive substrate. A manufacturing method is provided.

  In the illumination optical apparatus of the present invention, the annular illumination pupil distribution in the circumferentially polarized state can be formed without substantially generating a light amount loss by the action of the light beam conversion element. That is, in the illumination optical device of the present invention, it is possible to form a ring-shaped illumination pupil distribution in a circumferentially polarized state while suppressing loss of light quantity satisfactorily.

  Further, in the exposure apparatus and the exposure method using the illumination optical apparatus of the present invention, since the illumination optical apparatus that can form a ring-shaped illumination pupil distribution in a circumferentially polarized state while suppressing light amount loss favorably, A fine pattern in an arbitrary direction can be transferred faithfully and with high throughput under appropriate illumination conditions, and thus a good device can be manufactured with high throughput.

  Embodiments of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a view schematically showing a configuration of an exposure apparatus provided with an illumination optical apparatus according to an embodiment of the present invention. In FIG. 1, the Z axis along the normal direction of the wafer W, which is a photosensitive substrate, the Y axis in the direction parallel to the plane of FIG. 1 in the plane of the wafer W, and the plane of the wafer W in FIG. The X axis is set in the direction perpendicular to the paper surface. The exposure apparatus of this embodiment includes a light source 1 for supplying exposure light (illumination light).

  As the light source 1, for example, a KrF excimer laser light source that supplies light with a wavelength of 248 nm, an ArF excimer laser light source that supplies light with a wavelength of 193 nm, or the like can be used. A substantially parallel light beam emitted from the light source 1 along the Z direction has a rectangular cross section extending along the X direction and is incident on the beam expander 2 including a pair of lenses 2a and 2b. Each lens 2a and 2b has a negative refracting power and a positive refracting power in the plane of FIG. 1 (in the YZ plane), respectively. Accordingly, the light beam incident on the beam expander 2 is enlarged in the plane of FIG. 1 and shaped into a light beam having a predetermined rectangular cross section.

  A substantially parallel light beam through a beam expander 2 as a shaping optical system is deflected in the Y direction by a bending mirror 3, and then a quarter wavelength plate 4a, a half wavelength plate 4b, a depolarizer (non-polarization element). The light enters the afocal lens 6 via 4c and the diffractive optical element 5 for annular illumination. Here, the quarter-wave plate 4a, the half-wave plate 4b, and the depolarizer 4c constitute a polarization state switching unit 4 as described later. The afocal lens 6 is set so that the front focal position and the position of the diffractive optical element 5 substantially coincide with each other, and the rear focal position and the position of the predetermined surface 7 indicated by a broken line in the drawing substantially coincide with each other. System (non-focal optical system).

  In general, a diffractive optical element is formed by forming a step having a pitch of the wavelength of exposure light (illumination light) on a substrate, and has a function of diffracting an incident beam to a desired angle. Specifically, the diffractive optical element 5 for annular illumination forms an annular light intensity distribution in the far field (or Fraunhofer diffraction region) when a parallel light beam having a rectangular cross section is incident. It has a function. Accordingly, the substantially parallel light beam incident on the diffractive optical element 5 as the light beam conversion element forms an annular light intensity distribution on the pupil plane of the afocal lens 6 and then exits from the afocal lens 6 as a substantially parallel light beam. Is done.

  In the optical path between the front lens group 6a and the rear lens group 6b of the afocal lens 6, the conical axicon system 8, the first cylindrical lens pair 9, The second cylindrical lens pair 10 is disposed, and the detailed configuration and operation thereof will be described later. Hereinafter, in order to simplify the description, the basic configuration and operation will be described ignoring the operations of the conical axicon system 8, the first cylindrical lens pair 9, and the second cylindrical lens pair 10.

  The light beam that has passed through the afocal lens 6 enters a micro fly's eye lens (or fly eye lens) 12 as an optical integrator through a zoom lens 11 for variable σ value. The micro fly's eye lens 12 is an optical element composed of a large number of microlenses having positive refractive powers arranged vertically and horizontally and densely. In general, a micro fly's eye lens is configured by, for example, performing etching treatment on a plane-parallel plate to form a micro lens group.

  Here, each micro lens constituting the micro fly's eye lens is smaller than each lens element constituting the fly eye lens. Further, unlike a fly-eye lens composed of lens elements isolated from each other, a micro fly-eye lens is formed integrally with a large number of micro lenses (micro refractive surfaces) without being isolated from each other. However, the micro fly's eye lens is the same wavefront division type optical integrator as the fly eye lens in that lens elements having positive refractive power are arranged vertically and horizontally.

  The position of the predetermined surface 7 is disposed in the vicinity of the front focal position of the zoom lens 11, and the incident surface of the micro fly's eye lens 12 is disposed in the vicinity of the rear focal position of the zoom lens 11. In other words, the zoom lens 11 arranges the predetermined surface 7 and the incident surface of the micro fly's eye lens 12 substantially in a Fourier transform relationship, and consequently the pupil surface of the afocal lens 6 and the incident surface of the micro fly's eye lens 12. Are arranged almost conjugate optically.

  Accordingly, on the incident surface of the micro fly's eye lens 12, for example, a ring-shaped illumination field centered on the optical axis AX is formed in the same manner as the pupil surface of the afocal lens 6. The entire shape of the annular illumination field changes in a similar manner depending on the focal length of the zoom lens 11. Each microlens constituting the micro fly's eye lens 12 has a rectangular cross section similar to the shape of the illumination field to be formed on the mask M (and thus the shape of the exposure region to be formed on the wafer W).

  The light beam incident on the micro fly's eye lens 12 is two-dimensionally divided by a large number of microlenses, and an illumination field formed by the incident light beam is formed on the rear focal plane (and thus the illumination pupil) as shown in FIG. A secondary light source having substantially the same light intensity distribution, that is, a secondary light source composed of a ring-shaped substantial surface light source centered on the optical axis AX is formed. A light beam from a secondary light source (generally an illumination pupil distribution formed on or near the pupil plane of the illumination optical device) formed on the rear focal plane of the micro fly's eye lens 12 is converted into a beam splitter 13a and condenser optics. After passing through the system 14, the mask blind 15 is illuminated in a superimposed manner.

  Thus, a rectangular illumination field corresponding to the shape and focal length of each microlens constituting the micro fly's eye lens 12 is formed on the mask blind 15 as an illumination field stop. The internal configuration and operation of the polarization monitor 13 incorporating the beam splitter 13a will be described later. The light beam that has passed through the rectangular opening (light transmitting portion) of the mask blind 15 receives the light condensing action of the imaging optical system 16 and then illuminates the mask M on which a predetermined pattern is formed in a superimposed manner.

  That is, the imaging optical system 16 forms an image of the rectangular opening of the mask blind 15 on the mask M. The light beam that has passed through the pattern of the mask M forms an image of the mask pattern on the wafer W, which is a photosensitive substrate, via the projection optical system PL. Thus, by performing batch exposure or scan exposure while driving and controlling the wafer W two-dimensionally in a plane (XY plane) orthogonal to the optical axis AX of the projection optical system PL, each exposure region of the wafer W is masked. M patterns are sequentially exposed.

  In the polarization state switching means 4, the quarter wavelength plate 4a is configured so that the crystal optical axis is rotatable about the optical axis AX, and converts incident elliptically polarized light into linearly polarized light. The half-wave plate 4b is configured such that the crystal optical axis is rotatable about the optical axis AX, and changes the polarization plane of incident linearly polarized light. The depolarizer 4c includes a wedge-shaped quartz prism (not shown) having a complementary shape and a wedge-shaped quartz prism (not shown). The quartz prism and the quartz prism are configured to be detachable with respect to the illumination optical path as an integral prism assembly.

  When a KrF excimer laser light source or an ArF excimer laser light source is used as the light source 1, the light emitted from these light sources typically has a polarization degree of 95% or more, and the quarter-wave plate 4a has almost linearly polarized light. Light enters. However, when a right-angle prism as a back reflector is interposed in the optical path between the light source 1 and the polarization state switching means 4, the polarization plane of the incident linearly polarized light does not coincide with the P-polarization plane or the S-polarization plane. The linearly polarized light is changed to elliptically polarized light by total reflection at the right angle prism.

  In the polarization state switching means 4, for example, even if elliptically polarized light is incident due to total reflection by a right-angle prism, the linearly polarized light converted by the action of the quarter wavelength plate 4a is half wavelength plate. 4b. When the crystal optical axis of the half-wave plate 4b is set to make an angle of 0 degrees or 90 degrees with respect to the plane of polarization of the linearly polarized light incident thereon, the linearly polarized light incident on the half-wave plate 4b Passes through without changing the plane of polarization.

  In addition, when the crystal optical axis of the half-wave plate 4b is set to form an angle of 45 degrees with respect to the plane of polarization of the linearly polarized light incident thereon, the linearly polarized light incident on the half-wave plate 4b is It is converted into linearly polarized light whose polarization plane has changed by 90 degrees. Further, when the crystal optical axis of the crystal prism of the depolarizer 4c is set to form an angle of 45 degrees with respect to the plane of polarization of the linearly polarized light incident thereon, the linearly polarized light incident on the crystal prism is unpolarized light. Converted to non-polarized light.

  The polarization state switching means 4 is configured such that when the depolarizer 4c is positioned in the illumination optical path, the crystal optical axis of the quartz prism makes an angle of 45 degrees with respect to the polarization plane of the linearly polarized light that is incident. Incidentally, when the crystal optical axis of the crystal prism is set to make an angle of 0 degrees or 90 degrees with respect to the plane of polarization of the linearly polarized light incident thereon, the plane of polarization of the linearly polarized light incident on the crystal prism changes. It passes without any changes. Further, when the crystal optical axis of the half-wave plate 4b is set to make an angle of 22.5 degrees with respect to the plane of polarization of the linearly polarized light incident thereon, the linearly polarized light incident on the half-wave plate 4b is The light is converted into non-polarized light including a linearly polarized light component that passes through without changing its polarization plane and a linearly polarized light component whose polarization plane changes by 90 degrees.

  In the polarization state switching means 4, as described above, linearly polarized light is incident on the half-wave plate 4b. In order to simplify the following description, the polarization direction (direction of the electric field) in the Z direction in FIG. ) Linearly polarized light (hereinafter referred to as “Z-direction polarized light”) is incident on the half-wave plate 4b. When the depolarizer 4c is positioned in the illumination optical path, if the crystal optical axis of the half-wave plate 4b is set to make an angle of 0 degree or 90 degrees with respect to the polarization plane (polarization direction) of the Z-direction polarized light that is incident The Z-polarized light incident on the half-wave plate 4b passes through the Z-polarized light without changing the polarization plane and enters the quartz prism of the depolarizer 4c. The crystal optical axis of the quartz prism is set to make an angle of 45 degrees with respect to the polarization plane of the incident Z-direction polarized light. Therefore, the Z-polarized light incident on the quartz prism is converted into unpolarized light. Is done.

  The light depolarized through the quartz prism enters the diffractive optical element 5 in a non-polarized state through the quartz prism as a compensator for compensating the light traveling direction. On the other hand, when the crystal optical axis of the half-wave plate 4b is set to form an angle of 45 degrees with respect to the plane of polarization of the Z-direction polarized light that is incident, the Z-direction polarized light incident on the half-wave plate 4b is The polarization plane changes by 90 degrees, and becomes linearly polarized light (hereinafter referred to as “X direction polarization”) having a polarization direction (electric field direction) in the X direction in FIG. 1 and enters the quartz prism of the depolarizer 4c. . Since the crystal optical axis of the quartz prism is set to make an angle of 45 degrees with respect to the polarization plane of the incident X-direction polarized light, the X-direction polarized light incident on the quartz prism is converted into unpolarized light. The light is converted and enters the diffractive optical element 5 through the quartz prism in a non-polarized state.

  On the other hand, when the depolarizer 4c is retracted from the illumination optical path, the crystal optical axis of the half-wave plate 4b is set to make an angle of 0 degree or 90 degrees with respect to the polarization plane of the Z-direction polarized light that is incident. The Z-polarized light incident on the half-wave plate 4b passes through the Z-polarized light without changing its polarization plane, and enters the diffractive optical element 5 in the Z-polarized state. On the other hand, when the crystal optical axis of the half-wave plate 4b is set to form an angle of 45 degrees with respect to the plane of polarization of the Z-direction polarized light that is incident, the Z-direction polarized light incident on the half-wave plate 4b is The polarization plane changes by 90 degrees to become X-direction polarized light, and enters the diffractive optical element 5 in the X-direction polarization state.

  As described above, in the polarization state switching unit 4, the non-polarized light can be incident on the diffractive optical element 5 by inserting and positioning the depolarizer 4c in the illumination optical path. Further, the depolarizer 4c is retracted from the illumination optical path and the crystal optical axis of the half-wave plate 4b is set so as to make an angle of 0 degrees or 90 degrees with respect to the polarization plane of the Z-direction polarized light incident thereon. Directionally polarized light can be incident on the diffractive optical element 5. Further, by retracting the depolarizer 4c from the illumination optical path and setting the crystal optical axis of the half-wave plate 4b to be 45 degrees with respect to the polarization plane of the Z-direction polarization incident thereon, the light in the X-direction polarization state is set. Can be incident on the diffractive optical element 5.

  In other words, in the polarization state switching means 4, the polarization state of incident light to the diffractive optical element 5 (by the action of the polarization state switching means comprising the quarter wavelength plate 4 a, the half wavelength plate 4 b, and the depolarizer 4 c ( When a normal diffractive optical element other than the diffractive optical element for circumferential polarization annular illumination according to the present invention, which will be described later, is used, the polarization state of the light that illuminates the mask M and the wafer W is defined as a linearly polarized state It is possible to switch between polarization states, and in the case of a linear polarization state, it is possible to switch between polarization states orthogonal to each other (between Z-direction polarization and X-direction polarization).

  FIG. 3 is a diagram schematically showing the configuration of a conical axicon system disposed in the optical path between the front lens group and the rear lens group of the afocal lens in FIG. The conical axicon system 8 includes, in order from the light source side, a first prism member 8a having a flat surface facing the light source side and a concave conical refractive surface facing the mask side, and a convex conical shape facing the plane toward the mask side and the light source side. And a second prism member 8b facing the refractive surface.

  The concave conical refracting surface of the first prism member 8a and the convex conical refracting surface of the second prism member 8b are complementarily formed so as to be in contact with each other. Further, at least one of the first prism member 8a and the second prism member 8b is configured to be movable along the optical axis AX, and the concave conical refracting surface of the first prism member 8a and the second prism member 8b. The distance from the convex conical refracting surface is variable.

  Here, in a state where the concave conical refracting surface of the first prism member 8a and the convex conical refracting surface of the second prism member 8b are in contact with each other, the conical axicon system 8 functions and is formed as a parallel plane plate. There is no effect on the secondary light source in the annular zone. However, when the concave conical refracting surface of the first prism member 8a is separated from the convex conical refracting surface of the second prism member 8b, the conical axicon system 8 functions as a so-called beam expander. Therefore, the angle of the incident light beam on the predetermined surface 7 changes with the change in the interval of the conical axicon system 8.

  FIG. 4 is a diagram for explaining the action of the conical axicon system on the annular secondary light source. Referring to FIG. 4, the smallest annular zone-shaped secondary formed in a state where the distance between the conical axicon system 8 is zero and the focal length of the zoom lens 11 is set to the minimum value (hereinafter referred to as “standard state”). The light source 30a expands the interval of the conical axicon system 8 from zero to a predetermined value, so that its width (1/2 of the difference between the outer diameter and the inner diameter: indicated by an arrow in the figure) does not change. It changes into a secondary light source 30b having an annular shape in which both the outer diameter and the inner diameter are enlarged. In other words, the annular ratio (inner diameter / outer diameter) and size (outer diameter) both change without changing the width of the annular secondary light source due to the action of the conical axicon system 8.

  FIG. 5 is a diagram illustrating the action of the zoom lens on the annular secondary light source. Referring to FIG. 5, the annular secondary light source 30a formed in the standard state is enlarged in a similar manner by enlarging the focal length of the zoom lens 11 from the minimum value to a predetermined value. It changes into a ring-shaped secondary light source 30c. In other words, due to the action of the zoom lens 11, both the width and size (outer diameter) change without changing the annular ratio of the annular secondary light source.

  FIG. 6 is a diagram schematically showing the configuration of the first cylindrical lens pair and the second cylindrical lens pair arranged in the optical path between the front lens group and the rear lens group of the afocal lens in FIG. . In FIG. 6, a first cylindrical lens pair 9 and a second cylindrical lens pair 10 are arranged in order from the light source side. The first cylindrical lens pair 9 has, in order from the light source side, for example, a first cylindrical negative lens 9a having a negative refractive power in the YZ plane and having no refractive power in the XY plane, and also having a positive refractive power in the YZ plane. And a first cylindrical positive lens 9b having no refractive power in the XY plane.

  On the other hand, the second cylindrical lens pair 10 is, in order from the light source side, for example, the second cylindrical negative lens 10a having negative refractive power in the XY plane and having no refractive power in the YZ plane, and also positively refracting in the XY plane. And a second cylindrical positive lens 10b having a non-refractive power in the YZ plane. The first cylindrical negative lens 9a and the first cylindrical positive lens 9b are configured to rotate integrally around the optical axis AX. Similarly, the second cylindrical negative lens 10a and the second cylindrical positive lens 10b are configured to rotate integrally around the optical axis AX.

  Thus, in the state shown in FIG. 6, the first cylindrical lens pair 9 functions as a beam expander having power in the Z direction, and the second cylindrical lens pair 10 functions as a beam expander having power in the X direction. The power of the first cylindrical lens pair 9 and the power of the second cylindrical lens pair 10 are set to be the same.

  FIGS. 7 to 9 are diagrams for explaining the action of the first cylindrical lens pair and the second cylindrical lens pair with respect to the annular secondary light source. In FIG. 7, the power direction of the first cylindrical lens pair 9 makes an angle of +45 degrees around the optical axis AX with respect to the Z axis, and the power direction of the second cylindrical lens pair 10 goes around the optical axis AX with respect to the Z axis. Are set to form an angle of -45 degrees.

  Therefore, the power direction of the first cylindrical lens pair 9 and the power direction of the second cylindrical lens pair 10 are orthogonal to each other, and the power in the Z direction in the synthesis system of the first cylindrical lens pair 9 and the second cylindrical lens pair 10 is The power in the X direction is the same. As a result, in the perfect circle state shown in FIG. 7, the light beam passing through the synthesis system of the first cylindrical lens pair 9 and the second cylindrical lens pair 10 is subjected to an expanding action with the same power in the Z direction and the X direction. Thus, a secondary light source in the shape of a perfect ring zone is formed on the illumination pupil.

  On the other hand, in FIG. 8, the power direction of the first cylindrical lens pair 9 forms an angle of, for example, +80 degrees around the optical axis AX with respect to the Z axis, and the power direction of the second cylindrical lens pair 10 is with respect to the Z axis. For example, an angle of -80 degrees is set around the optical axis AX. Therefore, in the synthesis system of the first cylindrical lens pair 9 and the second cylindrical lens pair 10, the power in the X direction is larger than the power in the Z direction. As a result, in the horizontal elliptical state shown in FIG. 8, the light beam passing through the combined system of the first cylindrical lens pair 9 and the second cylindrical lens pair 10 has an expanding action with a greater power in the X direction than in the Z direction. As a result, a horizontally elongated secondary light source elongated in the X direction is formed on the illumination pupil.

  On the other hand, in FIG. 9, the power direction of the first cylindrical lens pair 9 forms an angle of, for example, +10 degrees around the optical axis AX with respect to the Z axis, and the power direction of the second cylindrical lens pair 10 is light with respect to the Z axis. For example, an angle of −10 degrees is set around the axis AX. Therefore, in the synthesis system of the first cylindrical lens pair 9 and the second cylindrical lens pair 10, the power in the Z direction is larger than the power in the X direction. As a result, in the vertical ellipse state shown in FIG. 9, the light beam passing through the combined system of the first cylindrical lens pair 9 and the second cylindrical lens pair 10 has an expanding action with greater power in the Z direction than in the X direction. As a result, a vertically elongated annular light source elongated in the Z direction is formed on the illumination pupil.

  Further, by setting the first cylindrical lens pair 9 and the second cylindrical lens pair 10 to an arbitrary state between the perfect circle state shown in FIG. 7 and the horizontal ellipse state shown in FIG. 8, various aspect ratios are met. A horizontally elongated secondary light source can be formed. Further, by setting the first cylindrical lens pair 9 and the second cylindrical lens pair 10 to any state between the perfect circle state shown in FIG. 7 and the vertical ellipse state shown in FIG. 9, various aspect ratios are obtained. A vertically long secondary light source having an annular zone can be formed.

  FIG. 10 is a perspective view schematically showing the internal configuration of the polarization monitor of FIG. Referring to FIG. 10, the polarization monitor 13 includes a first beam splitter 13 a disposed in the optical path between the micro fly's eye lens 12 and the condenser optical system 14. The first beam splitter 13a has, for example, a form of an uncoated plane parallel plate (that is, a bare glass) formed of quartz glass and has a function of extracting reflected light having a polarization state different from the polarization state of incident light from the optical path. .

  The light extracted from the optical path by the first beam splitter 13a enters the second beam splitter 13b. Similar to the first beam splitter 13a, the second beam splitter 13b has a form of an uncoated parallel flat plate formed of, for example, quartz glass, and generates reflected light having a polarization state different from the polarization state of incident light. It has a function. The P-polarized light for the first beam splitter 13a is set to be S-polarized light for the second beam splitter 13b, and the S-polarized light for the first beam splitter 13a is set to be P-polarized light for the second beam splitter 13b.

  The light transmitted through the second beam splitter 13b is detected by the first light intensity detector 13c, and the light reflected by the second beam splitter 13b is detected by the second light intensity detector 13d. The outputs of the first light intensity detector 13c and the second light intensity detector 13d are respectively supplied to a control unit (not shown). The control unit drives the quarter wavelength plate 4a, the half wavelength plate 4b, and the depolarizer 4c constituting the polarization state switching unit 4 as necessary.

  As described above, in the first beam splitter 13a and the second beam splitter 13b, the reflectance for P-polarized light and the reflectance for S-polarized light are substantially different. Therefore, in the polarization monitor 13, the reflected light from the first beam splitter 13a is, for example, about 10% of the S-polarized component of the incident light to the first beam splitter 13a (the S-polarized component with respect to the first beam splitter 13a, P-polarized component for the two beam splitter 13b) and, for example, a P-polarized component of about 1% of the incident light on the first beam splitter 13a (P-polarized component for the first beam splitter 13a and S-polarized light for the second beam splitter 13b) Component).

  The reflected light from the second beam splitter 13b is, for example, a P-polarized component of about 10% × 1% = 0.1% of the incident light to the first beam splitter 13a (a P-polarized component with respect to the first beam splitter 13a). The S-polarized component for the second beam splitter 13b) and the S-polarized component of, for example, about 1% × 10% = 0.1% of the incident light to the first beam splitter 13a (the S-polarized component for the first beam splitter 13a) And a P-polarized component for the second beam splitter 13b).

  Thus, in the polarization monitor 13, the first beam splitter 13 a has a function of extracting reflected light having a polarization state different from the polarization state of incident light from the optical path according to the reflection characteristics. As a result, the output of the first light intensity detector 13c (information on the intensity of transmitted light of the second beam splitter 13b, that is, the first beam splitter is slightly affected by the polarization fluctuation due to the polarization characteristic of the second beam splitter 13b. Based on information on the intensity of light in the polarization state substantially the same as the reflected light from 13a), the polarization state (polarization degree) of the incident light to the first beam splitter 13a, and in turn the polarization state of the illumination light to the mask M, is determined. Can be detected.

  The polarization monitor 13 is set so that the P-polarized light for the first beam splitter 13a becomes S-polarized light for the second beam splitter 13b and the S-polarized light for the first beam splitter 13a becomes P-polarized light for the second beam splitter 13b. ing. As a result, based on the output of the second light intensity detector 13d (information on the intensity of light sequentially reflected by the first beam splitter 13a and the second beam splitter 13b), the polarization of the incident light to the first beam splitter 13a. The light quantity (intensity) of the incident light on the first beam splitter 13a and, consequently, the light quantity of the illumination light on the mask M can be detected without being substantially affected by the change in state.

  In this way, the polarization monitor 13 is used to detect the polarization state of the light incident on the first beam splitter 13a, thereby determining whether the illumination light on the mask M is in a desired non-polarization state or a linear polarization state. can do. When the control unit confirms that the illumination light to the mask M (and thus the wafer W) is not in the desired non-polarized state or linearly polarized state based on the detection result of the polarization monitor 13, the polarization state switching means 4 The quarter wave plate 4a, the half wave plate 4b, and the depolarizer 4c that constitute the light beam can be driven and adjusted so that the state of the illumination light on the mask M can be adjusted to a desired non-polarization state or a linear polarization state.

  In addition, instead of the diffractive optical element 5 for annular illumination, quadrupole illumination can be performed by setting a diffractive optical element (not shown) for quadrupole illumination in the illumination optical path. The diffractive optical element for quadrupole illumination has a function of forming a quadrupole light intensity distribution in the far field when a parallel light beam having a rectangular cross section is incident. Therefore, the light beam that has passed through the diffractive optical element for quadrupole illumination has a quadrupole illumination field composed of, for example, four circular illumination fields centered on the optical axis AX on the incident surface of the micro fly's eye lens 12. Form. As a result, the same quadrupole secondary light source as the illumination field formed on the incident surface is also formed on the rear focal plane of the micro fly's eye lens 12.

  Moreover, instead of the diffractive optical element 5 for annular illumination, normal circular illumination can be performed by setting a diffractive optical element (not shown) for circular illumination in the illumination optical path. The diffractive optical element for circular illumination has a function of forming a circular light intensity distribution in the far field when a parallel light beam having a rectangular cross section is incident. Therefore, the light beam that has passed through the diffractive optical element for circular illumination forms a quadrupole illumination field on the incident surface of the micro fly's eye lens 12, for example, a circular illumination field centered on the optical axis AX. As a result, a secondary light source having the same circular shape as the illumination field formed on the incident surface is also formed on the rear focal plane of the micro fly's eye lens 12.

  Furthermore, by replacing the diffractive optical element 5 for annular illumination with another diffractive optical element (not shown) for multi-pole illumination in the illumination optical path, various multi-pole illumination (bi-polar illumination, 8 Polar lighting etc.). Similarly, various forms of modified illumination can be performed by setting a diffractive optical element (not shown) having appropriate characteristics in the illumination optical path instead of the diffractive optical element 5 for annular illumination.

  In this embodiment, instead of the diffractive optical element 5 for annular illumination, a so-called circumferential polarization annular illumination diffractive optical element 50 is set in the illumination optical path to pass through the annular secondary light source. Modified illumination in which the light beam is set in the circumferential polarization state, that is, circumferential polarization annular illumination can be performed. FIG. 11 is a diagram schematically showing the configuration of a diffractive optical element for circumferentially polarized annular illumination according to this embodiment. FIG. 12 is a diagram schematically showing a ring-shaped secondary light source set in the circumferential polarization state.

  Referring to FIGS. 11 and 12, the diffractive optical element 50 for circumferentially polarized annular illumination according to the present embodiment has the same rectangular cross section and has a thickness along the light transmission direction (Y direction). The four basic elements 50A to 50D having different lengths (lengths in the optical axis direction) are arranged vertically and horizontally and densely. Here, the thickness of the first basic element 50A is the largest, the thickness of the fourth basic element 50D is the smallest, and the thickness of the second basic element 50B is set larger than the thickness of the third basic element 50C. .

  The diffractive optical element 50 includes substantially the same number of the first basic element 50A, the second basic element 50B, the third basic element 50C, and the fourth basic element 50D, and the four types of basic elements 50A to 50D are arranged almost randomly. ing. Further, a diffractive surface (shown by hatching in the figure) is formed on the mask side of each basic element 50A to 50D, and the diffractive surface of each basic element 50A to 50D is orthogonal to the optical axis AX (not shown in FIG. 11). They are aligned along one plane. As a result, the surface on the mask side of the diffractive optical element 50 is planar, but the surface on the light source side of the diffractive optical element 50 is uneven due to the difference in thickness of the basic elements 50A to 50D.

  The diffractive surface of the first basic element 50A forms a pair of arcuate regions 31A that are symmetrical with respect to the Z-direction axis passing through the optical axis AX in the annular secondary light source 31 shown in FIG. It is configured. That is, as shown in FIG. 13, the first basic element 50A is symmetrical with respect to the Z-axis axis passing through the optical axis AX to the far field (and thus the far field of each basic element 50A to 50D) 50E of the diffractive optical element 50. It has a function of forming a pair of arc-shaped light intensity distributions 32A (corresponding to a pair of arc-shaped regions 31A).

  The diffractive surface of the second basic element 50B is symmetrical with respect to an axis obtained by rotating an axis in the Z direction passing through the optical axis AX by −45 degrees around the Y axis (rotated 45 degrees counterclockwise in FIG. 12). This arc-shaped region 31B is formed. That is, as shown in FIG. 14, the second basic element 50B has a pair of circular arcs symmetrical with respect to an axis obtained by rotating the axis in the Z direction passing through the optical axis AX by −45 degrees around the Y axis. The light intensity distribution 32B (corresponding to the pair of arcuate regions 31B) is formed.

  The diffractive surface of the third basic element 50C is configured to form a pair of arcuate regions 31C that are symmetric with respect to an axis in the X direction passing through the optical axis AX. That is, as shown in FIG. 15, the third basic element 50C has a pair of arc-shaped light intensity distributions 32C (a pair of arc-shaped regions 31C) symmetrical to the far field 50E with respect to the axis in the X direction passing through the optical axis AX. For example).

  The diffractive surface of the fourth basic element 50D is a pair of circles symmetrical with respect to an axis obtained by rotating the axis in the Z direction passing through the optical axis AX by +45 degrees around the Y axis (rotated 45 degrees clockwise in FIG. 12). An arcuate region 31D is formed. That is, as shown in FIG. 16, the fourth basic element 50D has a pair of arcuate shapes symmetrical with respect to an axis obtained by rotating the axis in the Z direction passing through the optical axis AX by +45 degrees around the Y axis. It has a function of forming a light intensity distribution 32D (corresponding to a pair of arcuate regions 31D). The arc-shaped regions 31A to 31D have substantially the same size, and the eight arc-shaped regions 31A to 31D do not overlap with each other and are not separated from each other, and are annular-shaped secondary with the optical axis AX as the center. A light source 31 is configured.

  In the present embodiment, each of the basic elements 50A to 50D is made of quartz that is an optical material having optical activity, and the crystal optical axis of each of the basic elements 50A to 50D is set to substantially coincide with the optical axis AX. Yes. Hereinafter, with reference to FIG. 17, the optical rotation of the crystal will be briefly described. Referring to FIG. 17, a parallel flat plate-like optical member 35 made of quartz having a thickness d is arranged so that the crystal optical axis thereof coincides with the optical axis AX. In this case, due to the optical rotation of the optical member 35, the incident linearly polarized light is emitted in a state where the polarization direction is rotated by θ around the optical axis AX.

At this time, the rotation angle θ in the polarization direction due to the optical rotation of the optical member 35 is expressed by the following equation (1) by the thickness d of the optical member 35 and the optical rotation ρ of the crystal.
θ = d · ρ (1)
In general, the optical rotation power ρ of a crystal tends to increase as the wavelength of the light used decreases, but according to the description on page 167 of “Applied Optics II”, the optical rotation power of the crystal with respect to light having a wavelength of 250.3 nm. ρ is 153.9 degrees / mm.

  In the present embodiment, as shown in FIG. 13, in the first basic element 50A, when linearly polarized light having a polarization direction in the Z direction is incident, the first basic element 50A is a direction obtained by rotating the Z direction by +180 degrees around the Y axis. The thickness dA is set so as to emit linearly polarized light having a polarization direction in the direction. As a result, the polarization direction of the light beam passing through the pair of arc-shaped light intensity distributions 32A formed in the far field 50E is also the Z direction, and the polarization direction of the light beam passing through the pair of arc-shaped regions 31A shown in FIG. Z direction.

  As shown in FIG. 14, in the second basic element 50B, when linearly polarized light having a polarization direction in the Z direction is incident, the Z direction is rotated by +135 degrees around the Y axis, that is, the Z direction is around the Y axis. The thickness dB is set so that linearly polarized light having a polarization direction in a direction rotated by −45 degrees is emitted. As a result, the polarization direction of the light beam passing through the pair of arc-shaped light intensity distributions 32B formed in the far field 50E is also the direction obtained by rotating the Z direction by −45 degrees around the Y axis, and the pair of pairs shown in FIG. The polarization direction of the light beam passing through the arc-shaped region 31A is also a direction obtained by rotating the Z direction by −45 degrees around the Y axis.

  As shown in FIG. 15, when the linearly polarized light having the polarization direction in the Z direction is incident, the third basic element 50C changes the polarization direction in the direction obtained by rotating the Z direction by +90 degrees around the Y axis, that is, in the X direction. The thickness dC is set so as to emit linearly polarized light. As a result, the polarization direction of the light beam passing through the pair of arc-shaped light intensity distributions 32C formed in the far field 50E is also the X direction, and the polarization direction of the light beam passing through the pair of arc-shaped regions 31C shown in FIG. X direction.

  As shown in FIG. 16, in the fourth basic element 50D, when linearly polarized light having a polarization direction in the Z direction is incident, linear polarization having a polarization direction in a direction obtained by rotating the Z direction by +45 degrees around the Y axis. The thickness dD is set so as to emit the light. As a result, the polarization direction of the light beam passing through the pair of arc-shaped light intensity distributions 32D formed in the far field 50E is also the direction obtained by rotating the Z direction by +45 degrees around the Y axis, and the pair of circles shown in FIG. The polarization direction of the light beam passing through the arc-shaped region 31D is also a direction obtained by rotating the Z direction by +45 degrees around the Y axis.

  In the present embodiment, during circumferential polarization annular illumination, a diffractive optical element 50 for circumferential polarization annular illumination is set in the illumination optical path, and linearly polarized light having a polarization direction in the Z direction is applied to the diffractive optical element 50. Make it incident. As a result, an annular secondary light source (annular illumination pupil distribution) 31 is formed on the rear focal plane of the micro fly's eye lens 12 (that is, the illumination pupil or its vicinity), as shown in FIG. The light beam passing through the annular secondary light source 31 is set in the circumferential polarization state.

  In the circumferential polarization state, the light beams passing through the arc-shaped regions 31A to 31D constituting the annular secondary light source 31 have the optical axis AX at the center position along the circumferential direction of each of the arc-shaped regions 31A to 31D. A linearly polarized state having a polarization direction substantially coincident with the tangent of the center circle is obtained.

  As described above, in the present embodiment, the light beam conversion element 50 for forming a predetermined light intensity distribution on a predetermined surface based on the incident light beam is formed of an optical material having optical rotation, and the The first basic element 50A for forming the first region distribution 32A of the predetermined light intensity distribution; and formed of an optical material having optical rotation, and out of the predetermined light intensity distribution based on the incident light flux The second basic element 50B for forming the second region distribution 32B is provided, and the thicknesses of the first basic element 50A and the second basic element 50B along the light transmission direction are different from each other.

  With such a configuration, in the present embodiment, unlike the conventional technique in which a large light amount loss occurs in the aperture stop, the light amount loss is substantially reduced by the diffractive action and the optical rotatory action of the diffractive optical element 50 as a light beam conversion element. The annular secondary light source 31 in the circumferentially polarized state can be formed without being generated.

  Here, according to a preferred aspect of the present embodiment, the thickness of the first basic element 50A and the thickness of the second basic element 50B are such that the linearly polarized light that forms the first region distribution 32A when linearly polarized light is incident thereon. The polarization direction and the polarization direction of the linearly polarized light forming the second region distribution 32B are set to be different. In addition, the first region distribution 32A and the second region distribution 32B are positioned in at least a part of a predetermined ring zone region that is a predetermined ring zone region centered on a predetermined point on a predetermined plane. It is preferable that the light beam passing through the two-region distribution 32B has a polarization state mainly composed of linearly polarized light whose polarization direction is the circumferential direction of the predetermined annular region.

  In this case, the predetermined light intensity distribution has substantially the same shape as that of the predetermined ring zone region, and the polarization state of the light beam passing through the first region distribution 32A is along the circumferential direction of the first region distribution 32A. The polarization state of the light beam that has a linearly polarized light component substantially coincident with the tangential direction of a circle centered on a predetermined point at the center position and passes through the second region distribution 32B is along the circumferential direction of the second region distribution 32B. It is preferable to have a linearly polarized light component substantially coincident with a tangential direction of a circle centered on a predetermined point at the center position. Alternatively, the predetermined light intensity distribution is multipolar distributed in a predetermined annular region, and the polarization state of the light beam passing through the first region distribution is at a central position along the circumferential direction of the first region distribution. The polarization state of the light beam having a linearly polarized light component substantially coincident with the tangential direction of the circle centered on the predetermined point and passing through the second region distribution is a predetermined point at the center position along the circumferential direction of the second region distribution. It is preferable to have a linearly polarized light component that substantially coincides with the tangential direction of the circle centered at.

  Further, according to a preferred aspect of the present embodiment, the first basic element and the second basic element are formed of an optical material having an optical rotation power of 100 degrees / mm or more with respect to light of the wavelength used. The first basic element and the second basic element are preferably formed of quartz. Moreover, it is preferable that the light beam conversion element includes substantially the same number of first basic elements and second basic elements. The first basic element and the second basic element preferably have a diffractive action or a refractive action.

  According to a preferred aspect of the present embodiment, the first basic element forms at least two first region distributions on a predetermined plane based on the incident light beam, and the second basic element is at least based on the incident light beam. It is preferable to form two second region distributions on a predetermined surface. Further, the third basic element 50C is formed of an optical material having optical rotation, and forms the third region distribution 32C of the predetermined light intensity distribution based on the incident light beam, and the optical material having optical rotation. It is preferable to further include a fourth basic element 50D that is formed to form the fourth region distribution 32D of the predetermined light intensity distribution based on the incident light flux.

  In the present embodiment, the light beam conversion element 50 for forming a predetermined light intensity distribution having a shape different from the cross-sectional shape of the incident light beam on the predetermined surface based on the incident light beam is provided on the predetermined surface. A diffractive surface or a refracting surface is provided to form a light intensity distribution, and the predetermined light intensity distribution is distributed over at least a part of the predetermined annular zone area that is a predetermined annular zone centered on a predetermined point on the predetermined plane. The light beam from the light beam conversion element passing through the predetermined ring zone region has a polarization state mainly composed of linearly polarized light whose polarization direction is the circumferential direction of the predetermined ring zone region.

  With such a configuration, in the present embodiment, unlike the conventional technique in which a large light amount loss occurs in the aperture stop, the light amount loss is substantially reduced by the diffractive action and the optical rotatory action of the diffractive optical element 50 as a light beam conversion element. The annular secondary light source 31 in the circumferentially polarized state can be formed without being generated.

  According to a preferred aspect of the present embodiment, the predetermined light intensity distribution has a multipolar shape or an annular shape. The light beam conversion element is preferably formed of an optical material having optical activity.

  The illumination optical device according to the present embodiment is an illumination optical device that illuminates a surface to be irradiated based on a light beam from a light source, and the light source is used to form an illumination pupil distribution at or near the illumination pupil of the illumination optical device. Is provided with the above-described light beam conversion element. With such a configuration, the illumination optical device of the present embodiment can form a ring-shaped illumination pupil distribution in a circumferentially polarized state while suppressing a light amount loss satisfactorily.

  Here, the light beam conversion element is preferably configured to be exchangeable with other light beam conversion elements having different characteristics. The optical system further includes a wavefront splitting type optical integrator disposed in the optical path between the light beam conversion element and the irradiated surface, and the light beam conversion element has a predetermined light intensity distribution on the incident surface of the optical integrator based on the incident light beam. Is preferably formed.

  According to a preferred aspect of the illumination optical apparatus of the present embodiment, at least one of the light intensity distribution on the predetermined surface and the polarization state of the light beam from the light beam conversion element passing through the predetermined ring zone region is a light source. Is set in consideration of the influence of the optical member disposed in the optical path between the surface and the irradiated surface. Moreover, it is preferable to set the polarization state of the light beam from the light beam conversion element so that the light irradiated on the irradiated surface is in a polarization state mainly composed of S-polarized light.

  Moreover, the exposure apparatus of this embodiment is provided with the above-mentioned illumination optical apparatus for illuminating a mask, and exposes the pattern of a mask on a photosensitive substrate. Here, at least one of the light intensity distribution on the predetermined surface and the polarization state of the light beam from the light beam conversion element passing through the predetermined ring zone region is disposed in the optical path between the light source and the photosensitive substrate. It is preferable to set in consideration of the influence of the optical member. Moreover, it is preferable to set the polarization state of the light beam from the light beam conversion element so that the light irradiated to the photosensitive substrate is in a polarization state mainly composed of S-polarized light.

  Further, the exposure method of the present embodiment includes an illumination process for illuminating the mask using the above-described illumination optical device, and an exposure process for exposing the pattern of the mask onto the photosensitive substrate. Here, at least one of the light intensity distribution on the predetermined surface and the polarization state of the light beam from the light beam conversion element passing through the predetermined ring zone region is disposed in the optical path between the light source and the photosensitive substrate. It is preferable to set in consideration of the influence of the optical member. Moreover, it is preferable to set the polarization state of the light beam from the light beam conversion element so that the light irradiated to the photosensitive substrate is in a polarization state mainly composed of S-polarized light.

  In other words, in the illumination optical device according to the present embodiment, it is possible to form a ring-shaped illumination pupil distribution in a circumferentially polarized state while suppressing light amount loss satisfactorily. As a result, the exposure apparatus of the present embodiment uses an illumination optical apparatus that can form a ring-shaped illumination pupil distribution in a circumferentially polarized state while suppressing the light amount loss satisfactorily. Thus, a fine pattern in any direction can be transferred faithfully and with high throughput.

  In the circumferential polarization annular illumination based on the annular illumination pupil distribution in the circumferential polarization state, the light irradiated on the wafer W as the irradiated surface is in a polarization state mainly composed of S-polarized light. Here, the S-polarized light is linearly polarized light having a polarization direction in a direction perpendicular to the incident surface (polarized light having an electric vector oscillating in a direction perpendicular to the incident surface). However, the incident surface is defined as a surface including the normal of the boundary surface at that point and the incident direction of light when the light reaches the boundary surface of the medium (surface to be irradiated: the surface of the wafer W). The

  In the above-described embodiment, four types of basic elements 50A to 50D having the same rectangular cross section are randomly arranged in the vertical and horizontal directions and densely in the same number, thereby diffractive optical elements for circumferentially polarized annular illumination. 50. However, the present invention is not limited to this, and various modifications can be made with respect to the number of basic elements, the cross-sectional shape, the number of types, the arrangement, and the like.

  Further, in the above-described embodiment, by using the diffractive optical element 50 including the four types of basic elements 50A to 50D, the eight arc-shaped regions 31A to 31D arranged without overlapping each other and without being separated from each other, An annular secondary light source 31 centering on the optical axis AX is configured. However, the present invention is not limited to this, and various modifications can be made with respect to the number, shape, arrangement, and the like of the regions forming the annular secondary light source.

  Specifically, as shown in FIG. 18A, for example, by using a diffractive optical element composed of four types of basic elements, a circumferential polarization state composed of eight arc-shaped regions separated from each other along the circumferential direction. An octupole secondary light source 33a can also be formed. Further, as shown in FIG. 18B, for example, a diffractive optical element composed of four types of basic elements is used to form a quadrupolar shape in a circumferential polarization state composed of four arc-shaped regions spaced apart from each other along the circumferential direction. The secondary light source 33b can also be formed. In these octupole secondary light sources or quadrupole secondary light sources, the shape of each region is not limited to an arc shape, and may be, for example, a circular shape, an elliptical shape, or a fan shape. Further, as shown in FIG. 19, for example, using a diffractive optical element composed of four types of basic elements, a ring-shaped secondary light source in a circumferential polarization state composed of eight arc-shaped regions overlapping each other along the circumferential direction. 33c can also be formed.

  In addition to a quadrupole or octupole secondary light source having a circumferential polarization state composed of four or eight regions spaced apart from each other along the circumferential direction, as shown in FIG. A hexapolar secondary light source having a circumferential polarization state composed of six regions spaced apart from each other may be formed. In addition, as shown in FIG. 20 (b), a multipolar secondary light source having a circumferential polarization state composed of a plurality of regions spaced apart from each other along the circumferential direction, and a non-polarization state comprising a region on the optical axis or A secondary light source having a secondary light source on the central pole in a linear polarization state may be formed. Moreover, you may form the bipolar secondary light source of the circumferential direction polarization state which consists of two area | regions mutually spaced apart along the circumferential direction.

  In the above-described embodiment, as shown in FIG. 11, four types of basic elements 50A to 50D are individually formed, and the diffractive optical element 50 is configured by combining these elements. However, the present invention is not limited to this. For example, by performing an etching process on one quartz substrate, the diffraction surfaces on the emission side and the concave and convex surfaces on the incident side of the basic elements 50A to 50D are formed. Can also be configured integrally.

  In the above-described embodiment, the basic elements 50A to 50D (and thus the diffractive optical element 50) are formed using quartz. However, the present invention is not limited to this, and each basic element can be formed using other appropriate optical material having optical rotation. In this case, it is preferable to use an optical material having an optical rotatory power of 100 degrees / mm or more with respect to light of the wavelength used. That is, it is not preferable to use an optical material having a small optical rotation power because the thickness necessary for obtaining the required rotation angle in the polarization direction becomes too large, resulting in a loss of light quantity.

  In the above embodiment, the annular illumination pupil distribution (secondary light source) is formed. However, the present invention is not limited to this, and a circular illumination pupil distribution is formed in or near the illumination pupil. You can also. Moreover, in addition to the annular illumination pupil distribution and the multipolar illumination pupil distribution, for example, by forming a central region distribution including the optical axis, annular illumination with a so-called central pole or multiple poles with a central pole Lighting can also be performed.

  In the above-described embodiment, the illumination pupil distribution in the circumferential polarization state is formed at or near the illumination pupil. However, the polarization direction may change due to polarization aberration (retardation) of the optical system (illumination optical system or projection optical system) on the wafer side of the diffractive optical element as the light beam conversion element. In this case, it is necessary to appropriately set the polarization state of the light beam passing through the illumination pupil distribution formed in or near the illumination pupil in consideration of the influence of the polarization aberration of these optical systems.

  Further, in relation to the above-described polarization aberration, the reflected light is polarized in the polarization direction due to the polarization characteristics of the reflecting member disposed in the optical system (illumination optical system or projection optical system) on the wafer side of the light beam conversion element. Each may have a phase difference. Even in this case, it is necessary to appropriately set the polarization state of the light beam passing through the illumination pupil distribution or the illumination pupil distribution formed in the vicinity thereof in consideration of the influence of the phase difference caused by the polarization characteristics of the reflecting member.

  Further, due to the polarization characteristics of the reflecting member disposed in the optical system (illumination optical system or projection optical system) on the wafer side with respect to the light beam conversion element, the reflectance of the reflecting member may vary depending on the polarization direction. . In this case, in consideration of the reflectance for each polarization direction, it is preferable to offset the light intensity distribution formed at or near the illumination pupil, that is, to provide a distribution in the number of each basic element. In addition, the above method can be similarly applied when the transmittance in the optical system on the wafer side with respect to the light beam conversion element varies depending on the polarization direction.

  In the above-described embodiment, the surface on the light source side of the diffractive optical element 50 has a concavo-convex shape having a step due to the difference in thickness between the basic elements 50A to 50D. Therefore, as shown in FIG. 21, the correction member 36 is provided on the incident side of the basic element other than the first basic element 50A having the largest thickness, that is, the second basic element 50B, the third basic element 50C, and the fourth basic element 50D. In addition, the light source side (incident side) surface of the diffractive optical element 50 can also be configured to be planar. In this case, the correction member 36 is formed using an optical material having no optical rotation.

  In the above-described embodiment, an example is shown in which a light beam passing through an illumination pupil distribution formed in or near the illumination pupil has only a linearly polarized component along the circumferential direction. However, the present invention is not limited to this, and the required effect of the present invention can be obtained if the polarization state of the light beam passing through the illumination pupil distribution is a state in which the main component is linearly polarized light whose polarization direction is the circumferential direction. Can do.

  In the above-described embodiment, the light beam conversion element for forming the light intensity distribution having a shape different from the cross-sectional shape on the predetermined surface based on the incident light beam is composed of a plurality of types of basic elements having a diffractive action. A diffractive optical element is used. However, the present invention is not limited to this. For example, a plurality of types of basic elements having refractive surfaces that are optically substantially equivalent to the diffractive surfaces of the basic elements, that is, refractive optical elements composed of a plurality of types of basic elements having a refractive action are provided. It can also be used as a light beam conversion element.

  In the exposure apparatus according to the above-described embodiment, the illumination optical device illuminates the mask (reticle) (illumination process), and the projection optical system is used to expose the transfer pattern formed on the mask onto the photosensitive substrate (exposure). Step), a micro device (semiconductor element, imaging element, liquid crystal display element, thin film magnetic head, etc.) can be manufactured. Refer to the flowchart of FIG. 22 for an example of a method for obtaining a semiconductor device as a micro device by forming a predetermined circuit pattern on a wafer or the like as a photosensitive substrate using the exposure apparatus of the above-described embodiment. To explain.

  First, in step 301 of FIG. 22, a metal film is deposited on one lot of wafers. In the next step 302, a photoresist is applied on the metal film on the one lot of wafers. Thereafter, in step 303, the image of the pattern on the mask is sequentially exposed and transferred to each shot area on the wafer of one lot through the projection optical system using the exposure apparatus of the above-described embodiment. Thereafter, in step 304, the photoresist on the one lot of wafers is developed, and in step 305, the resist pattern is etched on the one lot of wafers to form a pattern on the mask. Corresponding circuit patterns are formed in each shot area on each wafer. Thereafter, a device pattern such as a semiconductor element is manufactured by forming a circuit pattern of an upper layer. According to the semiconductor device manufacturing method described above, a semiconductor device having an extremely fine circuit pattern can be obtained with high throughput.

  In the exposure apparatus of the above-described embodiment, a liquid crystal display element as a micro device can be obtained by forming a predetermined pattern (circuit pattern, electrode pattern, etc.) on a plate (glass substrate). Hereinafter, an example of the technique at this time will be described with reference to the flowchart of FIG. In FIG. 23, in the pattern forming process 401, a so-called photolithography process is performed in which the exposure pattern of the above-described embodiment is used to transfer and expose a mask pattern onto a photosensitive substrate (such as a glass substrate coated with a resist). . By this photolithography process, a predetermined pattern including a large number of electrodes and the like is formed on the photosensitive substrate. Thereafter, the exposed substrate undergoes steps such as a developing step, an etching step, and a resist stripping step, whereby a predetermined pattern is formed on the substrate, and the process proceeds to the next color filter forming step 402.

  Next, in the color filter forming step 402, a large number of sets of three dots corresponding to R (Red), G (Green), and B (Blue) are arranged in a matrix or three of R, G, and B A color filter is formed by arranging a plurality of stripe filter sets in the horizontal scanning line direction. Then, after the color filter forming step 402, a cell assembly step 403 is executed. In the cell assembly step 403, a liquid crystal panel (liquid crystal cell) is assembled using the substrate having the predetermined pattern obtained in the pattern formation step 401, the color filter obtained in the color filter formation step 402, and the like.

  In the cell assembly step 403, for example, liquid crystal is injected between the substrate having the predetermined pattern obtained in the pattern formation step 401 and the color filter obtained in the color filter formation step 402, and a liquid crystal panel (liquid crystal cell) is obtained. ). Thereafter, in a module assembling step 404, components such as an electric circuit and a backlight for performing a display operation of the assembled liquid crystal panel (liquid crystal cell) are attached to complete a liquid crystal display element. According to the above-described method for manufacturing a liquid crystal display element, a liquid crystal display element having an extremely fine circuit pattern can be obtained with high throughput.

In the above-described embodiment, KrF excimer laser light (wavelength: 248 nm) or ArF excimer laser light (wavelength: 193 nm) is used as the exposure light. However, the present invention is not limited to this, and other suitable laser light sources. For example, the present invention can also be applied to an F ₂ laser light source that supplies laser light having a wavelength of 157 nm. Furthermore, in the above-described embodiment, the present invention has been described by taking an exposure apparatus provided with an illumination optical apparatus as an example. Obviously you can do that.

  In the above-described embodiment, a so-called immersion method is applied in which the optical path between the projection optical system and the photosensitive substrate is filled with a medium (typically liquid) having a refractive index larger than 1.1. You may do it. In this case, as a method of filling the liquid in the optical path between the projection optical system and the photosensitive substrate, a method of locally filling the liquid as disclosed in International Publication No. WO99 / 49504, A method of moving a stage holding a substrate to be exposed as disclosed in Japanese Patent Application Laid-Open No. 6-124873 in a liquid bath, or a predetermined depth on a stage as disclosed in Japanese Patent Application Laid-Open No. 10-303114. A technique of forming a liquid tank and holding the substrate in the liquid tank can be employed. Here, International Publication Nos. WO99 / 49504, JP-A-6-124873, and JP-A-10-303114 are incorporated by reference.

As the liquid, it is preferable to use a liquid that is transmissive to exposure light and has a refractive index as high as possible, and is stable with respect to a photoresist applied to the projection optical system and the substrate surface, for example, KrF excimer laser light. When ArF excimer laser light is used as exposure light, pure water or deionized water can be used as the liquid. When F ₂ laser light is used as exposure light, a fluorine-based liquid such as fluorine oil or perfluorinated polyether (PFPE) that can transmit the F ₂ laser light may be used as the liquid.

It is a figure which shows schematically the structure of the exposure apparatus provided with the illumination optical apparatus concerning embodiment of this invention. It is a figure which shows the annular | circular shaped secondary light source formed in annular illumination. It is a figure which shows schematically the structure of the cone axicon system arrange | positioned in the optical path between the front side lens group and back side lens group of an afocal lens in FIG. It is a figure explaining the effect | action of a cone axicon system with respect to a ring-shaped secondary light source. It is a figure explaining the effect | action of the zoom lens with respect to an annular | circular shaped secondary light source. FIG. 2 is a diagram schematically showing a configuration of a first cylindrical lens pair and a second cylindrical lens pair arranged in an optical path between a front lens group and a rear lens group of an afocal lens in FIG. 1. It is a 1st figure explaining the effect | action of the 1st cylindrical lens pair and the 2nd cylindrical lens pair with respect to a ring-shaped secondary light source. It is a 2nd figure explaining the effect | action of the 1st cylindrical lens pair and the 2nd cylindrical lens pair with respect to an annular | circular shaped secondary light source. It is a 3rd figure explaining the effect | action of the 1st cylindrical lens pair and the 2nd cylindrical lens pair with respect to a ring-shaped secondary light source. FIG. 2 is a perspective view schematically showing an internal configuration of the polarization monitor of FIG. 1. It is a figure which shows schematically the structure of the diffractive optical element for the circumferential direction polarized ring illumination concerning this embodiment. It is a figure which shows roughly the annular secondary light source set to the circumferential direction polarization | polarized-light state. It is a figure explaining the effect | action of a 1st basic element. It is a figure explaining the effect | action of a 2nd basic element. It is a figure explaining the effect | action of a 3rd basic element. It is a figure explaining the effect | action of a 4th basic element. It is a figure explaining the optical rotatory power of quartz. A circumferentially polarized octupole secondary light source composed of eight arcuate regions spaced apart from each other along the circumferential direction and a circumferentially polarized state quadrupole composed of four arcuate regions spaced apart from each other along the circumferential direction It is a figure which shows a shape secondary light source. It is a figure which shows the annular | circular shaped secondary light source of the circumferential direction polarization state which consists of eight circular arc-shaped area | regions mutually overlapped along the circumferential direction. A circumferentially polarized light having a six-pole secondary light source in a circumferential polarization state composed of six arc-shaped regions spaced apart from each other along the circumferential direction, and a plurality of regions spaced apart from each other along the circumferential direction and a region on the optical axis It is a figure which shows the secondary light source of a state. It is a figure which shows the example which made the incident side surface of the diffraction optical element for circumferential direction polarized ring illumination flat. It is a flowchart of the method at the time of obtaining the semiconductor device as a microdevice. It is a flowchart of the method at the time of obtaining the liquid crystal display element as a microdevice.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Light source 4 Polarization state switching means 4a 1/4 wavelength plate 4b 1/2 wavelength plate 4c Depolarizer 5, 50 Diffractive optical element (light beam conversion element)
6 Afocal lens 8 Conical axicon system 9, 10 Cylindrical lens pair 11 Zoom lens 12 Micro fly eye lens 13 Polarization monitor 13a Beam splitter 14 Condenser optical system 15 Mask blind 16 Imaging optical system M Mask PL Projection optical system W Wafer

Claims (28)

In the illumination optical device that illuminates the illuminated surface based on the light flux from the light source,
Polarization state switching means for switching and emitting the polarization state of incident light; and
A light beam conversion element disposed in an optical path between the polarization state switching means and the irradiated surface;
Comprising said light beam conversion element, and a portion disposed optical system between the predetermined surface is the illumination pupil plane or plane in the vicinity of the front Symbol illumination optical apparatus,
The light beam conversion element is formed of an optical material having optical rotation, and is based on an incident linearly polarized light beam and cooperates with the partial optical system to form a first polarized light in a first region distribution on the predetermined surface. The first basic element for forming the first light intensity distribution of the state and an optical material having optical rotation, and based on the incident linearly polarized light beam , in cooperation with the partial optical system A second basic element for forming a second light intensity distribution of a second polarization state in a second region distribution on the predetermined plane,
The illumination optical apparatus according to claim 1, wherein the first basic element and the second basic element have different thicknesses along the optical axis direction of the illumination optical apparatus .
The thickness of the first basic element and the thickness of the second basic element are the polarization direction of the linearly polarized light that forms the first region distribution and the linearly polarized light that forms the second region distribution when linearly polarized light enters. The illumination optical device according to claim 1, wherein the polarization direction is set to be different from each other. The first region distribution and the second region distribution are positioned on at least a part of a predetermined annular region that is a predetermined annular region centered on a predetermined point on the predetermined surface ,
The light beam passing through the first region distribution and the second region distribution has a polarization state in which linearly polarized light whose polarization direction is a circumferential direction of the predetermined annular region is a main component. Or the illumination optical apparatus of 2. The light intensity distribution having the predetermined polarization characteristic has an outer shape that is substantially the same shape as the predetermined annular zone region,
The first polarization state of the light beam passing through the first region distribution is a linearly polarized light component that substantially coincides with the tangential direction of the circle centered on the predetermined point at the center position along the circumferential direction of the first region distribution. Have
The second polarization state of the light beam passing through the second region distribution is a linearly polarized light component that substantially coincides with the tangential direction of the circle centered on the predetermined point at the center position along the circumferential direction of the second region distribution. The illumination optical apparatus according to claim 3, wherein the illumination optical apparatus is provided. The light intensity distribution having the predetermined polarization characteristic is multipolar distributed in the predetermined annular zone region,
The first polarization state of the light beam passing through the first region distribution is a linearly polarized light component that substantially coincides with the tangential direction of the circle centered on the predetermined point at the center position along the circumferential direction of the first region distribution. Have
The second polarization state of the light beam passing through the second region distribution is a linearly polarized light component that substantially coincides with the tangential direction of the circle centered on the predetermined point at the center position along the circumferential direction of the second region distribution. The illumination optical apparatus according to claim 3, wherein the illumination optical apparatus is provided. The first basic element and the second basic element are made of an optical material having an optical rotatory power of 100 degrees / mm or more with respect to light of a use wavelength. The illumination optical device according to Item. The illumination optical apparatus according to claim 1, wherein the first basic element and the second basic element are made of quartz. The illumination optical device according to any one of claims 1 to 7, wherein the light beam conversion elements include substantially the same number of the first basic elements and the second basic elements. The illumination optical device according to any one of claims 1 to 8, wherein the first basic element and the second basic element are integrally formed. The light beam conversion element is formed of an optical material having optical rotation, and a third polarization state in a third region distribution among light intensity distributions having the predetermined polarization characteristics based on the incident linearly polarized light beam. A third basic element for forming a third light intensity distribution of
A fourth light intensity distribution in a fourth polarization state in a fourth region distribution among light intensity distributions formed of an optical material having optical rotation and having the predetermined polarization characteristics based on the incident linearly polarized light flux The illumination optical apparatus according to claim 1, further comprising: a fourth basic element for forming the first and second elements.
The thickness of the third basic element and the thickness of the fourth basic element are the polarization direction of the linearly polarized light that forms the third region distribution and the linearly polarized light that forms the fourth region distribution when linearly polarized light enters. The illumination optical apparatus according to claim 10, wherein the polarization direction is set to be different from each other. The third region distribution and the fourth region distribution are positioned on at least a part of a predetermined annular region that is a predetermined annular region centered on a predetermined point on the illumination pupil of the illumination optical device or a surface in the vicinity thereof. ,
11. The light flux passing through the third region distribution and the fourth region distribution has a polarization state mainly composed of linearly polarized light whose polarization direction is a circumferential direction of the predetermined annular region. Or the illumination optical apparatus of 11. The light intensity distribution having the predetermined polarization characteristic has an outer shape that is substantially the same shape as the predetermined annular zone region,
The third polarization state of the light beam passing through the third region distribution has a linearly polarized light component substantially coincident with a tangential direction of a circle centered on the predetermined point at the center position along the circumferential direction of the third region distribution. Have
The fourth polarization state of the light beam passing through the fourth region distribution has a linearly polarized light component substantially coincident with a tangential direction of a circle centered on the predetermined point at the center position along the circumferential direction of the fourth region distribution. The illumination optical apparatus according to claim 12, comprising: The light intensity distribution having the predetermined polarization characteristic is multipolar distributed in the predetermined annular zone region,
The third polarization state of the light beam passing through the third region distribution has a linearly polarized light component substantially coincident with a tangential direction of a circle centered on the predetermined point at the center position along the circumferential direction of the third region distribution. Have
The fourth polarization state of the light beam passing through the fourth region distribution has a linearly polarized light component substantially coincident with a tangential direction of a circle centered on the predetermined point at the center position along the circumferential direction of the fourth region distribution. The illumination optical apparatus according to claim 12, comprising: 15. The light flux conversion element according to any one of claims 10 to 14, wherein the light flux conversion element includes substantially the same number of the first basic element, the second basic element, the third basic element, and the fourth basic element. The illumination optical device described. The illumination according to any one of claims 10 to 15, wherein the first basic element, the second basic element, the third basic element, and the fourth basic element are integrally formed. Optical device. The illumination optical device according to any one of claims 1 to 16, wherein the light beam conversion element is configured to be exchangeable with another light beam conversion element having different characteristics . 18. The illumination optical apparatus according to claim 1, wherein the polarization state switching unit includes a quarter-wave plate configured such that a crystal optical axis is rotatable about an optical axis. . The illumination optical device according to any one of claims 1 to 18, wherein the polarization state switching unit includes a half-wave plate configured such that a crystal optical axis is rotatable about an optical axis. . The polarization state switching means is configured to be detachable from an illumination optical path, and has a depolarizer that converts incident light into unpolarized light. The illumination optical device according to 1. A wavefront splitting type optical integrator disposed in an optical path between the light flux conversion element and the irradiated surface;
21. The illumination optical apparatus according to claim 1, wherein the light beam conversion element forms a predetermined light intensity distribution on an incident surface of the optical integrator based on an incident light beam . The polarization state of a light beam from the light beam conversion element is set so that the light irradiated on the irradiated surface is in a polarization state mainly composed of S-polarized light . The illumination optical apparatus according to Item 1. 23. An exposure apparatus comprising the illumination optical apparatus according to claim 1 for illuminating a mask, and exposing a pattern of the mask onto a photosensitive substrate . 24. The exposure apparatus according to claim 23, wherein the polarization state of the light beam from the light beam conversion element is set so that the light applied to the photosensitive substrate is in a polarization state mainly composed of S-polarized light. . An exposure process comprising: an illumination process for illuminating a mask using the illumination optical apparatus according to any one of claims 1 to 22; and an exposure process for exposing a pattern of the mask onto a photosensitive substrate. Way . 26. The exposure method according to claim 25, wherein the polarization state of the light beam from the light beam conversion element is set so that the light applied to the photosensitive substrate is in a polarization state mainly composed of S-polarized light. . An illumination process for illuminating a mask using the illumination optical device according to any one of claims 1 to 22, and an exposure process for exposing a pattern of the mask onto a photosensitive substrate. Device manufacturing method . 28. The microdevice according to claim 27, wherein the polarization state of the light beam from the light beam conversion element is set so that the light applied to the photosensitive substrate is in a polarization state mainly composed of S-polarized light. Manufacturing method.

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