WO2018105658A1 - 近接露光装置及び近接露光方法 - Google Patents
近接露光装置及び近接露光方法 Download PDFInfo
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- WO2018105658A1 WO2018105658A1 PCT/JP2017/043825 JP2017043825W WO2018105658A1 WO 2018105658 A1 WO2018105658 A1 WO 2018105658A1 JP 2017043825 W JP2017043825 W JP 2017043825W WO 2018105658 A1 WO2018105658 A1 WO 2018105658A1
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- mask
- alignment mark
- workpiece
- mirror
- proximity exposure
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/20—Exposure; Apparatus therefor
- G03F7/2045—Exposure; Apparatus therefor using originals with apertures, e.g. stencil exposure masks
- G03F7/2047—Exposure with radiation other than visible light or UV light, e.g. shadow printing, proximity printing
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/08—Mirrors
- G02B5/10—Mirrors with curved faces
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F1/00—Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof
- G03F1/36—Masks having proximity correction features; Preparation thereof, e.g. optical proximity correction [OPC] design processes
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/20—Exposure; Apparatus therefor
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70058—Mask illumination systems
- G03F7/70141—Illumination system adjustment, e.g. adjustments during exposure or alignment during assembly of illumination system
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70058—Mask illumination systems
- G03F7/702—Reflective illumination, i.e. reflective optical elements other than folding mirrors, e.g. extreme ultraviolet [EUV] illumination systems
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70425—Imaging strategies, e.g. for increasing throughput or resolution, printing product fields larger than the image field or compensating lithography- or non-lithography errors, e.g. proximity correction, mix-and-match, stitching or double patterning
- G03F7/70433—Layout for increasing efficiency or for compensating imaging errors, e.g. layout of exposure fields for reducing focus errors; Use of mask features for increasing efficiency or for compensating imaging errors
- G03F7/70441—Optical proximity correction [OPC]
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70691—Handling of masks or workpieces
- G03F7/70775—Position control, e.g. interferometers or encoders for determining the stage position
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/708—Construction of apparatus, e.g. environment aspects, hygiene aspects or materials
- G03F7/70808—Construction details, e.g. housing, load-lock, seals or windows for passing light in or out of apparatus
- G03F7/70825—Mounting of individual elements, e.g. mounts, holders or supports
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F9/00—Registration or positioning of originals, masks, frames, photographic sheets or textured or patterned surfaces, e.g. automatically
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F9/00—Registration or positioning of originals, masks, frames, photographic sheets or textured or patterned surfaces, e.g. automatically
- G03F9/70—Registration or positioning of originals, masks, frames, photographic sheets or textured or patterned surfaces, e.g. automatically for microlithography
- G03F9/7003—Alignment type or strategy, e.g. leveling, global alignment
Definitions
- the present invention relates to a proximity exposure apparatus and a proximity exposure method.
- Patent Document 1 has a plurality of reflecting mirrors each provided with a mirror bending mechanism capable of correcting the curvature of the reflecting mirror, and one of the reflecting mirrors on the mask side has a mirror bending mechanism according to the strain amount of the workpiece. Drive to correct the distortion of the workpiece, while the other reflecting mirror corrects the curvature of one reflecting mirror, the mirror bending mechanism is driven to correct the curvature of the reflecting mirror and improve the illuminance distribution of exposure light An exposure apparatus is disclosed.
- the alignment mark on the workpiece side which is used for alignment when exposing the second and subsequent layers, may be transferred by being displaced due to distortion inherent to the workpiece.
- the curvature of the reflecting mirror is corrected according to the distortion of the workpiece, but the alignment mark is displaced by the amount of change in the declination angle during the exposure of the first layer. Is not considered.
- the distortion inherent to the workpiece cannot be determined only by the misalignment of the alignment mark.
- the present invention has been made in view of the above-mentioned problems, and a first object of the present invention is to accurately expose a mask pattern by correcting an alignment error caused by the principal ray angle of exposure light accompanying mirror bending.
- An object of the present invention is to provide a proximity exposure apparatus and a proximity exposure method capable of transfer.
- a second object of the present invention is to provide a proximity exposure apparatus and a proximity exposure method capable of correcting and transferring a shift amount caused by distortion inherent to a workpiece and accurately exposing and transferring a mask pattern.
- a work support part for supporting the work A mask support for supporting the mask;
- An illumination optical system having a light source, an integrator, and a plurality of reflecting mirrors that reflect exposure light from the light source;
- a proximity exposure apparatus that irradiates the work with exposure light from the light source through the mask and transfers the pattern of the mask to the work,
- At least one of the plurality of reflecting mirrors has a mirror bending mechanism capable of correcting the curvature of the reflecting mirror;
- An alignment camera capable of imaging the mask side alignment mark and the workpiece side alignment mark; The alignment mark on the workpiece side calculated from the angle of the principal ray of the exposure light irradiated to the workpiece when exposing the mask pattern of the first layer and the gap between the mask and the workpiece.
- a storage unit for storing an initial deviation component;
- the workpiece-side corrected alignment mark obtained by offsetting the initial deviation component with respect to the workpiece-side alignment mark observed by the alignment camera;
- a control device for alignment adjustment with the alignment mark on the mask side;
- a proximity exposure apparatus comprising: (2) When exposing the pattern of the mask after the second layer, the mirror bending mechanism is driven based on the amount of deviation at each position of the mask side alignment mark and the workpiece side correction alignment mark.
- the proximity exposure apparatus according to (1), wherein a curvature of the reflecting mirror is corrected.
- the proximity exposure apparatus characterized in that: (4) When the storage unit exposes the mask pattern in a predetermined layer after the second layer, the position of the mask-side alignment mark at the time of exposure with respect to the workpiece-side correction alignment mark The deviation component is averaged when a predetermined number of workpieces are exposed and recorded as a distortion-induced deviation component, The proximity exposure apparatus according to (1), wherein the control device corrects the curvature of the reflecting mirror by the mirror bending mechanism based on the distortion-induced deviation component.
- a work support part for supporting the work;
- a mask support for supporting the mask;
- An illumination optical system having a light source, an integrator, and a plurality of reflecting mirrors that reflect exposure light from the light source;
- a proximity exposure apparatus that irradiates the work with exposure light from the light source through the mask and transfers the pattern of the mask to the work,
- At least one of the plurality of reflecting mirrors has a mirror bending mechanism capable of correcting the curvature of the reflecting mirror; It has an alignment camera that can image the mask side alignment mark and the workpiece side alignment mark, When exposing the pattern of the mask in a predetermined layer after the second layer, a positional deviation component of the alignment mark on the workpiece side with respect to the alignment mark on the mask side at the time of exposure is determined with a predetermined number of workpieces.
- a storage unit that averages and records as a strain-induced deviation component when exposed, Based on the strain-induced deviation component, a control unit that corrects the curvature of the reflecting mirror by the mirror bending mechanism;
- a proximity exposure apparatus comprising: (6) a work support part for supporting the work; A mask support for supporting the mask; An illumination optical system having a light source, an integrator, and a plurality of reflecting mirrors that reflect exposure light from the light source; At least one of the plurality of reflecting mirrors has a mirror bending mechanism capable of correcting the curvature of the reflecting mirror; An alignment camera capable of imaging the mask side alignment mark and the workpiece side alignment mark;
- a proximity exposure method comprising: irradiating the work with exposure light from the light source through the mask using a proximity exposure apparatus comprising: The initial alignment mark on the workpiece side calculated from the angle of the principal ray of the exposure light applied to the workpiece when exposing the pattern of the first layer mask and the gap between the mask and the workpiece Storing a deviation component; When exposing the
- the proximity exposure method wherein the curvature of the reflecting mirror is corrected.
- the proximity exposure apparatus further includes a mirror moving mechanism capable of moving the reflecting mirror including the mirror bending mechanism in a direction perpendicular to the reflecting mirror, When exposing the mask pattern of the second and subsequent layers, an average shift amount is calculated based on the shift amount at each position of the mask side alignment mark and the workpiece side correction alignment mark, and the average The tilt of the reflecting mirror is changed by the mirror moving mechanism based on the shift amount, and the curvature of the reflecting mirror is corrected by the mirror bending mechanism based on the difference between the shift amount at each position and the average shift amount.
- the proximity exposure method according to (6).
- a positional deviation component between the correction mark on the workpiece side and the alignment mark on the mask side at the time of exposure is set to a predetermined value.
- a proximity exposure method comprising: irradiating the work with exposure light from the light source through the mask using a proximity exposure apparatus comprising: When exposing the pattern of the mask in a predetermined layer after the second layer, a positional deviation component of the alignment mark on the workpiece side with respect to the alignment mark on the mask side at the time of exposure is determined with a predetermined number of workpieces. A process of averaging and recording as a strain-induced deviation component when exposed; Correcting the curvature of the reflecting mirror by the mirror bending mechanism based on the strain-induced deviation component; A proximity exposure method comprising:
- the proximity exposure apparatus and the proximity exposure method of the present invention calculation is performed from the angle of the principal ray of the exposure light applied to the workpiece and the gap between the mask and the workpiece when the first mask pattern is exposed.
- the initial deviation component of the workpiece side alignment mark is stored, and when the mask pattern of the second and subsequent layers is exposed, the initial deviation component is offset with respect to the workpiece side alignment mark observed by the alignment camera.
- Alignment adjustment is performed using the obtained workpiece-side corrected alignment mark and the mask-side alignment mark. Thereby, the mask pattern can be accurately exposed and transferred by correcting the alignment error caused by the principal ray angle of the exposure light accompanying the mirror bending.
- the alignment on the mask side during exposure is performed with respect to the alignment mark on the workpiece side.
- the positional deviation component with respect to the mark is averaged when a predetermined number of workpieces are exposed and recorded as a distortion-induced deviation component, and the curvature of the reflecting mirror is corrected by a mirror bending mechanism based on the distortion-induced deviation component.
- the mask pattern can be accurately exposed and transferred by correcting the shift amount caused by the distortion inherent to the workpiece.
- FIG. 1 is a front view of an exposure apparatus according to a first embodiment of the present invention. It is a figure which shows the illumination optical system shown in FIG. (A) is a plan view showing a mirror deformation unit of the illumination optical system, (b) is a cross-sectional view taken along line AA in (a), and (c) is a cross-sectional view along B--B in (a). It is sectional drawing along a B line. It is a figure which shows the state which act
- FIG. 1 It is a schematic diagram which shows the state which the alignment mark of a mask shifts
- (A) is a schematic diagram showing a positional relationship between a mask-side alignment mark and a workpiece-side alignment mark observed by an alignment camera before alignment adjustment, and (b) is a mask-side alignment mark after alignment adjustment.
- FIG. 10 It is a schematic diagram which shows the positional relationship with the alignment mark by the side of a workpiece
- (A) is an example of the operation state of the mirror movement mechanism of FIG. 10, and
- (b) is another example of the operation state of the mirror movement mechanism of FIG.
- FIG. 5 is a schematic diagram showing a positional relationship between a mask side alignment mark and a work side alignment mark when a fourth work is exposed by averaging shift components of the first to third alignment marks.
- the proximity exposure apparatus PE uses a mask M smaller than the workpiece W as a material to be exposed, holds the mask M on a mask stage (mask support portion) 1, and holds the workpiece W on the workpiece stage (workpiece (workpiece)).
- the patterning light is irradiated from the illumination optical system 3 toward the mask M.
- the pattern of the mask M is exposed and transferred onto the workpiece W.
- the work stage 2 is moved stepwise with respect to the mask M in the two axial directions of the X axis direction and the Y axis direction, and exposure transfer is performed for each step.
- an X-axis stage feed mechanism 5 for moving the X-axis feed base 5a stepwise in the X-axis direction is installed on the apparatus base 4.
- a Y-axis stage feed mechanism 6 for step-moving the Y-axis feed base 6a in the Y-axis direction is installed in order to move the work stage 2 stepwise in the Y-axis direction.
- the work stage 2 is installed on the Y-axis feed base 6 a of the Y-axis stage feed mechanism 6.
- the work W On the upper surface of the work stage 2, the work W is held in a state of being sucked by a work chuck or the like. Further, a substrate side displacement sensor 15 for measuring the lower surface height of the mask M is disposed on the side portion of the work stage 2. Therefore, the substrate side displacement sensor 15 can move in the X and Y axis directions together with the work stage 2.
- a plurality of (four in the embodiment shown in the figure) X-axis linear guide rails 51 are arranged in the X-axis direction, and each guide rail 51 has a lower surface of the X-axis feed base 5 a.
- a slider 52 fixed to the bridge is straddled.
- the X-axis feed base 5 a is driven by the first linear motor 20 of the X-axis stage feed mechanism 5 and can reciprocate along the guide rail 51 in the X-axis direction.
- a plurality of guide rails 53 for Y-axis linear guides are arranged on the X-axis feed base 5a in the Y-axis direction.
- Each guide rail 53 has a slider 54 fixed to the lower surface of the Y-axis feed base 6a. Is straddled. Accordingly, the Y-axis feed base 6 a is driven by the second linear motor 21 of the Y-axis stage feed mechanism 6 and can reciprocate in the Y-axis direction along the guide rail 53.
- the vertical coarse motion device 7 having a relatively coarse positioning resolution but a large moving stroke and moving speed, and the vertical coarse motion Positioning with high resolution is possible compared with the apparatus 7, and a vertical fine movement apparatus 8 is provided for finely adjusting the gap between the opposing surfaces of the mask M and the work W to a predetermined amount by finely moving the work stage 2 up and down. .
- the vertical coarse movement device 7 moves the work stage 2 up and down with respect to the fine movement stage 6b by an appropriate drive mechanism provided on the fine movement stage 6b described later.
- the stage coarse movement shafts 14 fixed at four positions on the bottom surface of the work stage 2 are engaged with linear motion bearings 14a fixed to the fine movement stage 6b, and are guided in the vertical direction with respect to the fine movement stage 6b.
- it is desirable that the vertical coarse motion device 7 has high repeated positioning accuracy even if the resolution is low.
- the vertical fine movement device 8 includes a fixed base 9 fixed to the Y-axis feed base 6a, and a linear guide guide rail 10 attached to the fixed base 9 with its inner end inclined obliquely downward.
- a ball screw nut (not shown) is coupled to a slide body 12 that reciprocates along the guide rail 10 via a slider 11 straddling the guide rail 10, and an upper end surface of the slide body 12. Is in contact with the flange 12a fixed to the fine movement stage 6b so as to be slidable in the horizontal direction.
- the vertical fine movement device 8 may drive the slide body 12 by a linear motor instead of driving the slide body 12 by the motor 17 and the ball screw.
- the vertical fine movement device 8 is installed on one end side (left end side in FIG. 1) in the Y-axis direction of the Z-axis feed base 6a and two on the other end side, for a total of three units, and each is independently driven and controlled. It has become so. Accordingly, the vertical fine movement device 8 independently finely adjusts the heights of the three flanges 12 a based on the measurement results of the gap amounts between the mask M and the workpiece W at a plurality of locations by the gap sensor 27, and the workpiece stage 2. Fine-tune the height and inclination of In addition, when the height of the work stage 2 can be sufficiently adjusted by the vertical fine movement device 8, the vertical coarse movement device 7 may be omitted.
- a bar mirror (both not shown) facing the interferometer is installed.
- the bar mirror 19 facing the Y-axis laser interferometer 18 is arranged along the X-axis direction on one side of the Y-axis feed base 6a, and the bar mirror facing the X-axis laser interferometer is located on the Y-axis feed base 6a. It is arranged along the Y-axis direction on one end side.
- the Y-axis laser interferometer 18 and the X-axis laser interferometer are each arranged so as to always face the corresponding bar mirror and supported by the apparatus base 4.
- Two Y-axis laser interferometers 18 are installed apart from each other in the X-axis direction.
- the two Y-axis laser interferometers 18 detect the position of the Y-axis feed base 6a and consequently the work stage 2 in the Y-axis direction and the yawing error via the bar mirror 19.
- the X-axis laser interferometer detects the position of the X-axis feed base 5a and eventually the work stage 2 in the X-axis direction via the opposing bar mirror.
- the mask stage 1 is inserted in a X, Y, ⁇ direction (in the X, Y plane) by inserting a mask base frame 24 composed of a substantially rectangular frame body and a gap into a central opening of the mask base frame 24.
- the mask base frame 24 is held at a fixed position above the work stage 2 by a support column 4a protruding from the apparatus base 4.
- a frame-shaped mask holder 26 is provided on the lower surface of the central opening of the mask frame 25. That is, a plurality of mask holder suction grooves connected to a vacuum suction device (not shown) are provided on the lower surface of the mask frame 25, and the mask holder 26 is sucked to the mask frame 25 through the plurality of mask holder suction grooves. Retained.
- a plurality of mask suction grooves are provided on the lower surface of the mask holder 26 for sucking the peripheral portion of the mask M on which the mask pattern is not drawn.
- the mask M passes through the mask suction grooves. Then, it is detachably held on the lower surface of the mask holder 26 by a vacuum suction device (not shown).
- the mask frame 25 is equipped with a CCD camera 30 for alignment adjustment that images the alignment mark Ma of the mask M and the alignment mark Wa of the workpiece W.
- the proximity exposure apparatus PE includes a control device 90 that adjusts the alignment between the mask M and the workpiece W based on the distance between the alignment mark Ma of the mask M and the alignment mark Wa of the workpiece W taken by the CCD camera 30.
- the control device 90 includes a storage unit 91 that stores an initial deviation component of an alignment mark Wa of the workpiece W, which will be described later, and a distortion-induced deviation component caused by workpiece-specific distortion.
- the work stage 2 is provided with a plurality of illuminance sensors 95 as illuminance measuring means for measuring the illuminance of the exposure light irradiated on the work stage 2.
- the illumination optical system 3 of the exposure apparatus PE of the present embodiment includes a high-pressure mercury lamp 61 that is a light source for ultraviolet irradiation, and a reflector 62 that collects light emitted from the high-pressure mercury lamp 61.
- a multi-lamp unit 60 provided with a flat mirror 63 for changing the direction of the optical path EL, an exposure control shutter unit 64 for controlling the opening and closing of the irradiation optical path,
- An optical integrator 65 that emits light collected by the reflector 62 so as to have as uniform illumination distribution as possible in the irradiation region, a plane mirror 66 for changing the direction of the optical path EL emitted from the optical integrator 65, and a high pressure
- a collimation mirror 67 for irradiating light from the mercury lamp 61 as parallel light;
- a DUV cut filter, a polarization filter, and a band pass filter may be disposed between the optical integrator 65 and the exposure surface.
- the light source may be a single lamp as a high-pressure mercury lamp, or may be constituted by an LED.
- the exposure control shutter unit 64 When the exposure control shutter unit 64 is controlled to open during exposure, the light emitted from the multi-lamp unit 60 passes through the plane mirror 63, the optical integrator 65, the plane mirror 66, the collimation mirror 67, and the plane mirror 68. Then, the mask M held by the mask holder 26 and, consequently, the surface of the work W are irradiated as light for pattern exposure, and the exposure pattern of the mask M is exposed and transferred onto the work W.
- the plane mirrors 66 and 68 are made of a glass material formed in a rectangular shape in front view.
- the mask-side flat mirror 68 is supported on the mirror deformation unit holding frame 71 by a plurality of mirror deformation units 70 which are mirror bending mechanisms provided on the back surface side of the flat mirror 68.
- the mirror deformation unit 70 includes a plurality of pads 72, a plurality of holding members 73, and a plurality of motors 74 that are drive devices.
- the mirror deformation units 70 are provided at three locations near the center of the back surface of the flat mirror 68 and 16 peripheral portions.
- the pad 72 is fixed to the back surface of the flat mirror 68 with an adhesive.
- the pad 72 is fixed to the support portion 75 provided so as to sandwich the front and back surfaces of the flat mirror 68 with an adhesive.
- Each holding member 73 one end of which is fixed to the pad 72, is provided with a ball joint 76 as a bending mechanism that allows bending of ⁇ 0 ⁇ 5 deg or more at a position near the pad 72.
- a motor 74 is attached to the other end opposite to the holding frame 71.
- the holding member 73 at the center of the flat mirror 68 may be fixed to the mirror deformation unit holding frame 71.
- guide members 77 and 78 are attached to the rectangular mirror deformation unit holding frame 71 at positions on two sides orthogonal to each other, and on the side surface of the support portion 75 facing these guide members 77 and 78, A rolling member 79 is attached.
- a low friction mechanism 80 such as Teflon (registered trademark) is applied to the guide surfaces 77 a and 78 a of the guide members 77 and 78 that guide the rolling member 79.
- a plurality of contact sensors 81 are attached to the back surface of each position of the flat mirror 68 that reflects exposure light at the position of an alignment mark (not shown) on the mask side.
- the plane mirror 68 drives the motor 74 of each mirror deformation unit 70 while sensing the amount of displacement of the plane mirror 68 by the contact sensor 81, so that each mirror deformation unit 70 changes its length.
- the support part 75 is moved linearly. Due to the difference in length of each mirror deformation unit 70, the plane mirror 68 is guided by the two guide members 77 and 78 via the rolling member 79 provided on the support 75, and the curvature thereof is locally determined. It can be corrected.
- each motor 74 of the mirror deformation unit 70 of the plane mirror 68 is connected to a control unit 94 that sends a control signal to each motor 74 based on a command from the control device 90.
- the control unit 94 corrects the curvature of the flat mirror 68 to correct distortion of the workpiece W, which will be described later, and controls the motor 74 so that variation in the illuminance of the exposure light measured by the illuminance sensor 95 is suppressed. Give a signal.
- FIG. 5 is a flowchart showing an operation procedure of the mirror deformation unit 70.
- the pattern of the mask M is exposed on the workpiece W (step S1), and the exposure transfer pattern Wp is measured (step S2). Then, the length measurement result is compared with the design value (step S3), the correction amount is determined from the difference (step S4), the shape of the plane mirror 68 is determined (step S5), and each motor of the mirror deformation unit 70 is determined.
- the drive amount 74 is determined (step S6).
- each mirror deformation unit 70 is provided with a ball joint 76, so that the support side portion can be rotated three-dimensionally, and each pad 72 can be It can be inclined along the surface of the plane mirror 68. For this reason, the adhesive peeling between each pad 72 and the plane mirror 68 is prevented, and the stress of the plane mirror 68 between the pads 72 having different movement amounts is suppressed, and the average fracture stress value is made of a small glass material. Even when the curvature of the plane mirror 68 is locally corrected, the plane mirror 68 can be bent on the order of 10 mm without damaging the plane mirror 68, and the curvature can be greatly changed.
- the exposure position of the first layer without the base mark is determined by the mechanical accuracy of the proximity exposure apparatus PE.
- the alignment mark Wa of the workpiece W used in the exposure of each layer after the second layer is exposed.
- the exposure of the first layer for example, exposure to a rectangle may be slightly distorted due to the gap distribution of the exposure apparatus, the distribution of the declination angle of the illumination apparatus, the temperature distortion of the workpiece, and the like.
- the pattern of the exposure result of the first layer is measured, the deviation amount between the design coordinates and the measurement coordinates is obtained, and the mirror bending amount is determined based on the deviation amount. That is, the measurement result is brought close to the design coordinate value so that the deviation amount becomes zero.
- the angle (declination angle) of the principal ray EL is tilted with respect to the direction perpendicular to the workpiece W as shown in FIG.
- the mask M is formed at a position shifted from a position directly below the alignment mark Ma.
- the amount of deviation (initial deviation component) between the alignment mark Ma of the mask M and the alignment mark Wa of the workpiece W in the exposure of the first layer of workpiece W is obtained by the flowchart shown in FIG. That is, a declination angle (step S11) determined corresponding to the position of each alignment mark Ma is first obtained from the shape of the plane mirror 68 and the pattern of the mask M. Based on each declination angle and the exposure gap between the mask M and the workpiece W (step S12), an initial deviation component is calculated (step S13). This initial deviation component is stored in the storage unit 91.
- the alignment mark Ma of the mask M and the alignment mark Wa of the work W are simultaneously observed by the CCD camera 30 (step S21).
- a workpiece-side corrected alignment mark obtained by offsetting the initial deviation component (step S22) stored in the storage unit 91 with respect to the workpiece-side alignment mark Wa observed by the CCD camera 30 is used.
- the alignment correction amount is determined between the mask M and the alignment mark Ma (step S23).
- the mask M held on the mask stage (mask support) 1 is moved by a mask driving unit (not shown) to adjust the alignment (step S24).
- the alignment adjustment can be performed so that the alignment mark Ma of the mask M and the alignment mark Wa of the workpiece W are matched.
- the error due to the mirror deformation unit the error due to the alignment operation, the elongation due to the temperature change of the workpiece when the workpiece W is subjected to the exposure process, the change in the suction state, the characteristics of the workpiece, etc. Further distortion is included. For this reason, the position of each mark observed in actual exposure does not match all the alignment marks on the mask side and the correction alignment mark on the workpiece side even if the alignment adjustment is performed by offsetting the initial deviation component. Alignment adjustment is performed so that the total amount of deviation between the mask side alignment mark and the workpiece side alignment mark is minimized.
- each mirror deformation unit 70 by driving the motor of each mirror deformation unit 70 for each workpiece W based on the shift amount at each position of the mask side alignment mark and the workpiece side correction alignment mark, The plane mirror 68 is further corrected for mirror bending. Accordingly, it is possible to remove the shift amount due to the distortion inherent to the workpiece W and to expose the workpiece W in the second and subsequent layers.
- the initial deviation component of the alignment mark Wa on the workpiece W side calculated from the gap between the mask M and the workpiece W is stored, and is observed by the CCD camera 30 when exposing the pattern of the mask M on the second and subsequent layers.
- Alignment adjustment is performed using the workpiece W-side corrected alignment mark obtained by offsetting the initial deviation component with respect to the workpiece W-side alignment mark Wa and the mask M-side alignment mark Ma.
- the pattern of the mask M can be accurately exposed and transferred by correcting the alignment error caused by the angle of the principal ray EL of the exposure light accompanying the mirror bending.
- the mirror deformation unit 70 when exposing the pattern of the mask M of the second and subsequent layers, is based on the shift amount at each position between the mask side alignment mark Ma and the workpiece side correction alignment mark. Since the curvature of the plane mirror 68 is corrected by driving, the amount of deviation due to the distortion inherent to the workpiece W can be removed, and the exposure accuracy of the workpiece W in the second and subsequent layers can be further improved.
- the plane mirror 68 including the mirror deformation unit 70 further includes a plurality (four in this embodiment) of mirror movement mechanisms 80 that can move in the vertical direction with respect to the plane mirror 68. .
- the plurality of mirror moving units 80 are respectively attached to the four corners of the mirror deformation unit holding frame 71.
- the plurality of mirror moving units 80 for example, tilt the entire plane mirror 68 with respect to the X direction, the Y direction, or both the X and Y directions to change the angle of the principal ray from the light source. To be driven.
- the average deviation amount G of the deviation amounts at each position is expressed by the following equation.
- the mirror moving mechanism 80 is driven based on the x component and the y component of the average deviation amount G, and the inclination of the plane mirror 68 is changed.
- the correction angle ⁇ is expressed by the following equation when the exposure gap is gap ( ⁇ m).
- only one mirror moving mechanism 80 in the x direction may be moved as shown in FIG. 11A, or as shown in FIG.
- the mirror moving mechanisms 80 on both sides in the x direction may be moved A / 2 equally in the opposite direction.
- the difference Ai Pi ⁇ G between the shift amount Pi and the average shift amount G at each position is calculated, and the curvature of the plane mirror 68 is corrected by the mirror deformation unit 70 based on this difference.
- the average deviation amount is based on the deviation amount Pi at each position between the mask side alignment mark Ma and the workpiece side correction alignment mark.
- G is calculated, the inclination of the plane mirror 68 is changed by the mirror moving mechanism 80 based on the average deviation amount G, and the mirror deformation unit is based on the difference Ai between the deviation amount Pi and the average deviation amount G at each position.
- the curvature of the plane mirror 68 is corrected by 70. Accordingly, the deviation amount due to the distortion inherent to the workpiece W can be removed, and the exposure accuracy of the workpiece W in the second and subsequent layers can be further improved, and the stroke of the mirror deformation unit 70 can be set to be small. 68 bending can be suppressed.
- Other configurations and operations are the same as or equivalent to those of the first embodiment.
- the alignment mark Wa on the workpiece side also includes a shift component due to distortion inherent to the workpiece W, in this embodiment as well, this shift component is used for exposure of the second and subsequent workpieces W. The amount of deviation due to is corrected.
- the observed alignment mark Wa on the workpiece side includes a deviation component B due to distortion inherent to the workpiece W in addition to the initial deviation component A due to the mirror bending correction described above.
- the observed workpiece-side alignment mark Wa is offset by offsetting the initial deviation component A due to mirror bending correction.
- a correction alignment mark Wa ′ on the side is provided, and a deviation component B due to distortion inherent in the workpiece W is included therein.
- the positions of the workpiece-side corrected alignment marks Wa ′ (Wa1 ′, Wa2 ′, Wa3 ′) including the deviation component B are different for each workpiece W as shown in FIGS.
- this workpiece-side corrected alignment mark Wa ′ is exposed to a predetermined number of workpieces (three workpieces in FIG. 14) with respect to a positional deviation component from the mask-side alignment mark Ma at the time of exposure. Are averaged and recorded as a distortion-induced deviation component C (see FIG. 14D). Based on the distortion-induced deviation component C, the curvature of the plane mirror 68 is corrected by the mirror deformation unit 70.
- FIG. 12 is a flowchart showing a procedure for correcting the initial deviation component of the alignment mark and further correcting the deviation component due to the distortion inherent to the workpiece to expose the second and subsequent workpieces.
- the CCD camera 30 simultaneously observes the alignment mark Ma of the mask M and the alignment mark Wa of the workpiece W (step S31), and stores them in the storage unit 91 for the alignment mark Ma of the mask M.
- the auxiliary alignment mark Wa ′ is obtained by offsetting the initial deviation component (step S32).
- step S33 alignment adjustment is performed using the workpiece-side corrected alignment mark Wa ′ and the alignment mark Ma of the mask M (step S33).
- the mask stage (mask support part) 1 is moved (step S34), and the process returns to step S31.
- step S35 the average value of the deviation components B due to distortion inherent to each workpiece W (three workpieces W in FIG. 14) (distortion-induced deviation components). C) is calculated (step S36), and this is corrected as the alignment mark reference position (step S37).
- step S38 the correction conversion coefficient of the pattern correction position is calculated from the position of the alignment mark Wa (step S38), the exposure pattern correction amount is calculated (step S39), and the shape of the plane mirror 68 is determined (step S40).
- step S41 it is determined whether or not the operating range of the motor 74 for achieving the shape of the obtained flat mirror 68 exceeds the limit (step S41).
- step S41 it is difficult to correct the shape of the plane mirror 68 beyond this, so exposure transfer is performed in step S45.
- step S42 a further movement amount (difference) of the motor 74 is calculated (step S42), and the motor 74 is operated by the difference (step S43) to obtain a plane mirror.
- the shape of 68 is deformed (step S44), and the pattern of the mask M is exposed and transferred onto the workpiece W (step S45).
- step S46 the work stage (work support unit) 2 is moved to the next exposure position (step S47), the motor 74 is moved to the set position (step S48), and the process proceeds to step S31. Return and repeat the same operation.
- the proximity exposure apparatus PE and the proximity exposure method of the present embodiment when the pattern of the mask M in the second and subsequent layers is exposed, the workpiece side correction alignment mark Wa ′ is applied. Then, the positional deviation component with respect to the alignment mark Ma on the mask side at the time of exposure is averaged when a predetermined number of workpieces W are exposed and recorded as a distortion-induced deviation component C. Based on the distortion-induced deviation component C, The curvature of the plane mirror 68 is corrected by the mirror deformation unit 70. As a result, the shift component B caused by the distortion inherent in the workpiece W can be corrected and the pattern of the mask M can be accurately exposed and transferred.
- the corrected alignment mark Wa ′ on the workpiece side is offset and given in addition to the initial distortion components. Can do.
- the correction of the shift amount due to the distortion inherent to the workpiece may be performed independently of the correction of the alignment error due to the angle of the principal ray of the exposure light accompanying the mirror bending. That is, in the proximity exposure apparatus and the proximity exposure method of the present invention, when exposing the mask pattern in the second and subsequent predetermined layers, the alignment mark on the mask side during exposure is different from the alignment mark on the workpiece side. These positional deviation components are averaged when a predetermined number of workpieces are exposed and recorded as distortion-induced deviation components, and the curvature of the reflecting mirror is corrected by a mirror bending mechanism based on the distortion-induced deviation components. As a result, the mask pattern can be accurately exposed and transferred by correcting the shift amount due to the distortion inherent to the workpiece.
- Mask stage (mask support part) 2 Work stage (work support part) 3 Illumination optical system 30 CCD camera (alignment camera) 60 Multi lamp unit (light source) 65 Optical Integrator 68 Plane Mirror (Reflector) 70 Mirror deformation unit (mirror bending mechanism) 90 Control Device 91 Storage Unit EL Main Ray M Mask Ma Mask Side Alignment Mark PE Proximity Exposure Device W Work Wa, Wa1, Wa2, Wa3 Work Side Alignment Mark Wa ′, Wa1 ′, Wa2 ′, Wa3 ′ Work Side Assist Alignment mark
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Abstract
Description
特許文献1に記載の露光装置では、ワークの歪に応じて反射鏡の曲率を補正しているが、1層目の露光時のデクリネーション角の変化分だけ、アライメントマークが位置ずれする点を考慮していない。また、アライメントマークの位置ずれだけでは、ワーク固有のひずみを判断することができない。
(1) ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
を備え、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光装置であって、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラと、
1層目の前記マスクのパターンを露光する際における前記ワークに照射される前記露光光の主光線の角度と、前記マスク及び前記ワーク間のギャップとから計算される、前記ワーク側のアライメントマークの初期ずれ成分を記憶する記憶部と、
2層目以降の前記マスクのパターンを露光する際、前記アライメントカメラにより観測される前記ワーク側のアライメントマークに対して前記初期ずれ成分をオフセットして得られたワーク側の補正アライメントマークと、前記マスク側のアライメントマークとでアライメント調整する制御装置と、
を備えることを特徴とする近接露光装置。
(2) 前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、前記ミラー曲げ機構を駆動して前記反射鏡の曲率を補正することを特徴とする(1)に記載の近接露光装置。
(3) 前記ミラー曲げ機構を備えた前記反射鏡を、該反射鏡に対して垂直方向にそれぞれ移動可能なミラー移動機構をさらに備え、
前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、平均ずれ量を算出し、該平均ずれ量に基づいて前記ミラー移動機構によって前記反射鏡の傾きを変更すると共に、前記各位置でのずれ量と前記平均ずれ量との差分に基づいて前記ミラー曲げ機構によって前記反射鏡の曲率を補正することを特徴とする(1)に記載の近接露光装置。
(4) 前記記憶部は、2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側の補正アライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録し、
前記制御装置は、前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正することを特徴とする(1)に記載の近接露光装置。
(5) ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
を備え、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光装置であって、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラを備え、
2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側のアライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録する記憶部と、
前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正する制御部と、
を備えることを特徴とする近接露光装置。
(6) ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラと、
を備える近接露光装置を用いて、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光方法であって、
1層目のマスクのパターンを露光する際における前記ワークに照射される前記露光光の主光線の角度と、前記マスク及び前記ワーク間のギャップとから計算される、前記ワーク側のアライメントマークの初期ずれ成分を記憶する工程と、
2層目以降の前記マスクのパターンを露光する際、前記アライメントカメラにより観測される前記ワーク側のアライメントマークに対して前記初期ずれ成分をオフセットして得られたワーク側の補正アライメントマークと、前記マスク側のアライメントマークとでアライメント調整する工程と、
を備えることを特徴とする近接露光方法。
(7) 前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、前記ミラー曲げ機構を駆動して前記反射鏡の曲率を補正することを特徴とする(6)に記載の近接露光方法。
(8) 前記近接露光装置は、前記ミラー曲げ機構を備えた前記反射鏡を、該反射鏡に対して垂直方向にそれぞれ移動可能なミラー移動機構をさらに備え、
前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、平均ずれ量を算出し、該平均ずれ量に基づいて前記ミラー移動機構によって前記反射鏡の傾きを変更すると共に、前記各位置でのずれ量と前記平均ずれ量との差分に基づいて前記ミラー曲げ機構によって前記反射鏡の曲率を補正することを特徴とする(6)に記載の近接露光方法。
(9) 2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側の補正アライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録する工程と、
前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正する工程と、
を備えることを特徴とする(6)に記載の近接露光方法。
(10) ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラと、
を備える近接露光装置を用いて、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光方法であって、
2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側のアライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録する工程と、
前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正する工程と、
を備えることを特徴とする近接露光方法。
以下、本発明に係る露光装置の第1実施形態を図面に基づいて詳細に説明する。図1に示すように、近接露光装置PEは、被露光材としてのワークWより小さいマスクMを用い、マスクMをマスクステージ(マスク支持部)1で保持すると共に、ワークWをワークステージ(ワーク支持部)2で保持し、マスクMとワークWとを近接させて所定の露光ギャップで対向配置した状態で、照明光学系3からパターン露光用の光をマスクMに向けて照射することにより、マスクMのパターンをワークW上に露光転写する。また、ワークステージ2をマスクMに対してX軸方向とY軸方向の二軸方向にステップ移動させて、ステップ毎に露光転写が行われる。
なお、上下微動装置8は、モータ17とボールねじによってスライド体12を駆動する代わりに、リニアモータによってスライド体12を駆動するようにしてもよい。
なお、上下微動装置8によってワークステージ2の高さを十分に調整できる場合には、上下粗動装置7を省略してもよい。
次に、本発明の第2実施形態に係る近接露光装置及び近接露光方法について、図10及び図11を参照して説明する。なお、本実施形態は、平面ミラー68がミラー移動機構をさらに備える点において、及び、ミラーの制御方法において、第1実施形態のものと異なる。
ここで、各位置でのずれ量の平均ずれ量Gは、次式で表される。
その他の構成及び作用については、第1実施形態のものと同一又は同等である。
次に、本発明の第3実施形態に係る近接露光装置及び近接露光方法について、図12~図14を参照して説明する。なお、本実施形態では、ミラーの制御手法において、第1及び第2実施形態のものと異なる。
本出願は、2016年12月8日出願の日本特許出願2016-238738に基づくものであり、その内容はここに参照として取り込まれる。
2 ワークステージ(ワーク支持部)
3 照明光学系
30 CCDカメラ(アライメントカメラ)
60 マルチランプユニット(光源)
65 オプティカルインテグレータ
68 平面ミラー(反射鏡)
70 ミラー変形ユニット(ミラー曲げ機構)
90 制御装置
91 記憶部
EL 主光線
M マスク
Ma マスク側のアライメントマーク
PE 近接露光装置
W ワーク
Wa ,Wa1,Wa2,Wa3 ワーク側のアライメントマーク
Wa´,Wa1´,Wa2´,Wa3´ ワーク側の補助アライメントマーク
Claims (10)
- ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
を備え、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光装置であって、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラと、
1層目の前記マスクのパターンを露光する際における前記ワークに照射される前記露光光の主光線の角度と、前記マスク及び前記ワーク間のギャップとから計算される、前記ワーク側のアライメントマークの初期ずれ成分を記憶する記憶部と、
2層目以降の前記マスクのパターンを露光する際、前記アライメントカメラにより観測される前記ワーク側のアライメントマークに対して前記初期ずれ成分をオフセットして得られたワーク側の補正アライメントマークと、前記マスク側のアライメントマークとでアライメント調整する制御装置と、
を備えることを特徴とする近接露光装置。 - 前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、前記ミラー曲げ機構を駆動して前記反射鏡の曲率を補正することを特徴とする請求項1に記載の近接露光装置。
- 前記ミラー曲げ機構を備えた前記反射鏡を、該反射鏡に対して垂直方向にそれぞれ移動可能なミラー移動機構をさらに備え、
前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、平均ずれ量を算出し、該平均ずれ量に基づいて前記ミラー移動機構によって前記反射鏡の傾きを変更すると共に、前記各位置でのずれ量と前記平均ずれ量との差分に基づいて前記ミラー曲げ機構によって前記反射鏡の曲率を補正することを特徴とする請求項1に記載の近接露光装置。 - 前記記憶部は、2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側の補正アライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録し、
前記制御装置は、前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正することを特徴とする請求項1に記載の近接露光装置。 - ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
を備え、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光装置であって、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラを備え、
2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側のアライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録する記憶部と、
前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正する制御部と、
を備えることを特徴とする近接露光装置。 - ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラと、
を備える近接露光装置を用いて、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光方法であって、
1層目のマスクのパターンを露光する際における前記ワークに照射される前記露光光の主光線の角度と、前記マスク及び前記ワーク間のギャップとから計算される、前記ワーク側のアライメントマークの初期ずれ成分を記憶する工程と、
2層目以降の前記マスクのパターンを露光する際、前記アライメントカメラにより観測される前記ワーク側のアライメントマークに対して前記初期ずれ成分をオフセットして得られたワーク側の補正アライメントマークと、前記マスク側のアライメントマークとでアライメント調整する工程と、
を備えることを特徴とする近接露光方法。 - 前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、前記ミラー曲げ機構を駆動して前記反射鏡の曲率を補正することを特徴とする請求項6に記載の近接露光方法。
- 前記近接露光装置は、前記ミラー曲げ機構を備えた前記反射鏡を、該反射鏡に対して垂直方向にそれぞれ移動可能なミラー移動機構をさらに備え、
前記2層目以降の前記マスクのパターンを露光する際、前記マスク側のアライメントマークと前記ワーク側の補正アライメントマークとの各位置でのずれ量に基づいて、平均ずれ量を算出し、該平均ずれ量に基づいて前記ミラー移動機構によって前記反射鏡の傾きを変更すると共に、前記各位置でのずれ量と前記平均ずれ量との差分に基づいて前記ミラー曲げ機構によって前記反射鏡の曲率を補正することを特徴とする請求項6に記載の近接露光方法。 - 2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側の補正アライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録する工程と、
前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正する工程と、
を備えることを特徴とする請求項6に記載の近接露光方法。 - ワークを支持するワーク支持部と、
マスクを支持するマスク支持部と、
光源、インテグレータ、及び光源からの露光光を反射する複数の反射鏡を有する照明光学系と、
前記複数の反射鏡の内の少なくとも1つの前記反射鏡は、前記反射鏡の曲率を補正可能なミラー曲げ機構を有し、
マスク側のアライメントマークと、ワーク側のアライメントマークとを撮像可能なアライメントカメラと、
を備える近接露光装置を用いて、前記光源からの露光光を前記マスクを介して前記ワークに照射して前記マスクのパターンを前記ワークに転写する近接露光方法であって、
2層目以降の所定の層における前記マスクのパターンを露光する際、前記ワーク側のアライメントマークに対して、露光する際の前記マスク側のアライメントマークとの位置ずれ成分を、所定数のワークを露光した際に平均化してひずみ起因ずれ成分として記録する工程と、
前記ひずみ起因ずれ成分に基づいて、前記ミラー曲げ機構によって前記反射鏡の曲率を補正する工程と、
を備えることを特徴とする近接露光方法。
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