WO2023282109A1 - 露光装置及び検査方法 - Google Patents
露光装置及び検査方法 Download PDFInfo
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- WO2023282109A1 WO2023282109A1 PCT/JP2022/025555 JP2022025555W WO2023282109A1 WO 2023282109 A1 WO2023282109 A1 WO 2023282109A1 JP 2022025555 W JP2022025555 W JP 2022025555W WO 2023282109 A1 WO2023282109 A1 WO 2023282109A1
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Definitions
- a step-and-repeat projection exposure apparatus such as liquid crystal and organic EL display panels and semiconductor elements (integrated circuits, etc.
- And-scan projection exposure apparatuses so-called scanning steppers (also called scanners)
- This type of exposure apparatus projects and exposes a mask pattern for an electronic device onto a photosensitive layer coated on the surface of a substrate to be exposed (hereinafter simply referred to as a substrate) such as a glass substrate, semiconductor wafer, printed wiring board, or resin film. are doing.
- a digital mirror device or the like in which a large number of micromirrors that are slightly displaced are regularly arranged can be used instead of the mask substrate.
- a digital mirror device or the like in which a large number of micromirrors that are slightly displaced are regularly arranged.
- illumination light obtained by mixing light from a laser diode (LD) with a wavelength of 375 nm and light from an LD with a wavelength of 405 nm in a multimode fiber bundle is sent to a digital mirror.
- a device (DMD) is irradiated with light, and reflected light from each of a large number of tilt-controlled micromirrors is projected and exposed onto a substrate via an imaging optical system and a microlens array.
- the desired pattern may not be projected and exposed onto the substrate, so it is desired to identify the DMD containing the defective element.
- an exposure apparatus is an exposure apparatus that exposes an object to pattern light according to drawing data generated by a spatial light modulator having a plurality of elements, wherein the spatial light a data output unit that outputs the drawing data to a modulator; an illumination optical system that irradiates the spatial light modulator with illumination light; a first moving body that holds the object; a projection optical system that projects the image of the pattern light onto the object; a detection unit that detects the projected image of the pattern light; a determination unit that determines whether pattern light can be generated according to the drawing data output from the output unit.
- an inspection method comprises: a spatial light modulator having a plurality of elements that generate pattern light corresponding to drawing data; and an illumination optical system that irradiates the spatial light modulator with illumination light. and a projection optical system for projecting an image of the pattern light generated by the spatial light modulator onto an object mounted on a first moving body, inspecting the spatial light modulator of an exposure apparatus.
- the projected image of the pattern light cannot be detected, and the spatial light modulator cannot be driven according to the drawing data based on the detection result of the pattern light image. and determining whether it has defective elements.
- an inspection method comprises: a spatial light modulator having a plurality of elements that generate pattern light corresponding to drawing data; and an illumination optical system that irradiates the spatial light modulator with illumination light. and a projection optical system for projecting an image of the pattern light generated by the spatial light modulator onto an object mounted on a first moving body, inspecting the spatial light modulator of an exposure apparatus.
- the spatial light modulator is driven according to the drawing data by exposing the object to the image and measuring the object to which the image is exposed using a measuring device. and determining whether there are defective elements that cannot be processed.
- an inspection method comprises: a spatial light modulator having a plurality of elements that generate pattern light corresponding to drawing data; and an illumination optical system that irradiates the spatial light modulator with illumination light. and an inspection method for inspecting the spatial light modulator of an exposure apparatus having a projection optical system for projecting an image of the pattern light generated by the spatial light modulator onto an object mounted on a first moving body. exposing a photochromic element to the image of the pattern light generated by the spatial light modulator, and measuring the photochromic element exposed to the image of the pattern light using a measuring device, determining whether the spatial light modulator has defective elements that cannot be driven according to the drawing data.
- an exposure apparatus exposes an object to pattern light according to drawing data generated by a spatial light modulator having a plurality of elements, wherein the spatial light an illumination optical system that irradiates a modulator with illumination light; a first moving body that holds the object; a projection optical system that projects the pattern light generated by the spatial light modulator onto the object; a measurement unit that obtains a measurement result of the image of the pattern light above, wherein the measurement unit detects a defect in which the spatial light modulator cannot be driven according to the drawing data based on the measurement result. Measure whether or not there is an element.
- an exposure apparatus is an exposure apparatus that exposes an object to pattern light corresponding to drawing data generated by a spatial light modulator having a plurality of elements, wherein the spatial light an illumination optical system that irradiates a modulator with illumination light; a first moving body that holds a photochromic element; a projection optical system that projects the pattern light generated by the spatial light modulator onto the photochromic element; a measurement unit for obtaining a measurement result of the photochromic element on which the pattern light image is projected, the measurement unit driving the spatial light modulator according to the drawing data based on the measurement result. It is determined whether or not there is a defective element that cannot be processed.
- FIG. 1 is a perspective view showing an overview of the external configuration of an exposure apparatus according to one embodiment.
- FIG. 2 is a diagram showing an arrangement example of a DMD projection area projected onto a substrate by each projection unit of a plurality of exposure modules.
- FIG. 3 is a diagram for explaining the state of stitch exposure by each of the four specific projection areas in FIG.
- FIG. 4 is an optical layout diagram of a specific configuration of two exposure modules arranged in the X-axis direction (scanning exposure direction) viewed in the XZ plane.
- FIG. 5A is a diagram schematically showing the DMD
- FIG. 5B is a diagram showing the DMD when the power is OFF
- FIG. FIG. 5D is a diagram for explaining the mirror in the OFF state.
- FIG. 5A is a diagram schematically showing the DMD
- FIG. 5B is a diagram showing the DMD when the power is OFF
- FIG. 5D is a diagram for explaining the mirror in the OFF state.
- FIG. 6 is a diagram schematically showing a state in which the DMD and the illumination unit are tilted by an angle ⁇ k within the XY plane.
- FIG. 7 is a diagram for explaining in detail the imaging state of the micromirrors of the DMD by the projection unit.
- FIG. 8 is a diagram showing a schematic configuration of an alignment device provided on a calibration reference portion attached to the edge of the substrate holder of the exposure apparatus.
- FIG. 9 is a diagram of the substrate holder viewed from the +Z direction.
- FIG. 10(A) is a diagram showing a schematic configuration of an inspection apparatus including a magnifying imaging system provided in an inspection section provided at the end of the substrate holder, and FIG.
- FIG. 1 is a diagram showing a schematic configuration of an inspection apparatus that does not include an enlarging imaging system and is provided in an inspection section provided in .
- FIG. 11 is a functional block diagram of an inspection control device provided in the exposure apparatus.
- FIG. 12 is a flowchart illustrating an example of processing executed by the inspection control device.
- FIG. 13 is a flowchart showing details of the inspection process.
- FIG. 14A is a diagram showing an image of the first inspection pattern projected onto the imaging element when the DMD has no defective elements
- FIG. 14C shows an image of a first inspection pattern projected onto one pixel of an imaging device
- FIG. 14C shows an image of a second inspection pattern projected onto the imaging device when there is no defective element in the DMD;
- FIG. 14A is a diagram showing an image of the first inspection pattern projected onto the imaging element when the DMD has no defective elements
- FIG. 14C shows an image of a first inspection pattern projected onto one pixel of an imaging device
- FIG. 14C shows
- FIG. 14(D) is a diagram showing an image of the second inspection pattern projected onto one pixel of the imaging element surrounded by the dotted line in FIG. 14(C).
- FIG. 15(A) is a diagram showing a plurality of elements included in a DMD region corresponding to one pixel of an image sensor
- FIG. 15(B) illustrates a case where the plurality of elements of the DMD are divided into blocks. It is a figure to do.
- FIG. 16 is a diagram showing multiple elements of the DMD corresponding to one pixel of the imaging element.
- FIG. 17A is a diagram showing a first modified example of the images of the first and second inspection patterns projected onto the imaging element when the DMD has no defective elements.
- FIG. 17B is a diagram showing a second modification of images of the first and second inspection patterns projected when there is no defective element on the DMD.
- a pattern exposure apparatus (hereinafter simply referred to as an exposure apparatus) according to one embodiment will be described with reference to the drawings.
- FIG. 1 is a perspective view showing an overview of the external configuration of an exposure apparatus EX according to one embodiment.
- the exposure apparatus EX is an apparatus that forms and projects, onto a substrate to be exposed, exposure light whose intensity distribution in space is dynamically modulated by a spatial light modulator (SLM).
- SLM spatial light modulator
- Examples of spatial light modulators include liquid crystal devices, digital micromirror devices (DMDs), magneto-optical spatial light modulators (MOSLMs), and the like.
- the exposure apparatus EX according to this embodiment includes the DMD 10 as a spatial light modulator, but may include other spatial light modulators.
- the exposure apparatus EX is a step-and-scan projection exposure apparatus (scanner) that exposes a rectangular glass substrate used in a display device (flat panel display) or the like. be.
- the glass substrate is a flat panel display substrate P having at least one side length or diagonal length of 500 mm or more and a thickness of 1 mm or less.
- the exposure device EX exposes a photosensitive layer (photoresist) formed on the surface of the substrate P with a constant thickness to a projected image of a pattern created by the DMD.
- the substrate P unloaded from the exposure apparatus EX after exposure is sent to predetermined process steps (film formation step, etching step, plating step, etc.) after the development step.
- the exposure apparatus EX includes a pedestal 2 placed on active vibration isolation units 1a, 1b, 1c, and 1d (1d is not shown), a platen 3 placed on the pedestal 2, and An XY stage 4A (first driving unit) that can move two-dimensionally, a substrate holder 4B (first moving body) that sucks and holds a substrate P (object) on a plane on the XY stage 4A, a substrate holder 4B (substrate P) is provided with a stage device composed of laser length measurement interferometers (hereinafter simply referred to as interferometers) IFX and IFY1 to IFY4 for measuring the two-dimensional movement position.
- interferometers laser length measurement interferometers
- the XY plane of the orthogonal coordinate system XYZ is set parallel to the flat surface of the surface plate 3 of the stage device, and the XY stage 4A is set to be translatable within the XY plane.
- the direction parallel to the X-axis of the coordinate system XYZ is set as the scanning movement direction of the substrate P (XY stage 4A) during scanning exposure.
- the movement position of the substrate P in the X-axis direction is sequentially measured by the interferometer IFX, and the movement position in the Y-axis direction is sequentially measured by at least one (preferably two) of the four interferometers IFY1 to IFY4. be.
- the substrate holder 4B is configured to be slightly movable in the direction of the Z-axis perpendicular to the XY plane with respect to the XY stage 4A and to be slightly inclined in any direction with respect to the XY plane, and projected onto the surface of the substrate P. Focus adjustment and leveling (parallelism) adjustment with respect to the imaging plane of the pattern are actively performed. Further, the substrate holder 4B is configured to be slightly rotatable ( ⁇ z rotation) about an axis parallel to the Z axis in order to actively adjust the tilt of the substrate P within the XY plane.
- the exposure apparatus EX further includes an optical surface plate 5 that holds a plurality of exposure (drawing) module groups MU(A), MU(B), and MU(C), and a main column that supports the optical surface plate 5 from the pedestal 2. 6a, 6b, 6c, 6d (6d is not shown).
- Each of the plurality of exposure module groups MU(A), MU(B), and MU(C) is attached to the +Z direction side of the optical platen 5 .
- Each of the plurality of exposure module groups MU(A), MU(B), and MU(C) is attached to the +Z direction side of the optical surface plate 5, and an illumination unit ILU that receives illumination light from the optical fiber unit FBU.
- each of the exposure module groups MU(A), MU(B), and MU(C) serves as a light modulating section that reflects the illumination light from the illumination unit ILU in the -Z direction and makes it enter the projection unit PLU. of DMD 10.
- MU(A), MU(B), and MU(C) serves as a light modulating section that reflects the illumination light from the illumination unit ILU in the -Z direction and makes it enter the projection unit PLU. of DMD 10.
- a plurality of alignment systems (microscopes) ALG for detecting alignment marks formed at a plurality of predetermined positions on the substrate P are attached to the -Z direction side of the optical platen 5 of the exposure apparatus EX.
- Confirmation (calibration) of the relative positional relationship within the XY plane of each detection field of the alignment system ALG, from each projection unit PLU of the exposure module groups MU(A), MU(B), and MU(C) To confirm (calibrate) the baseline error between each projection position of the projected pattern image and the position of each detection field of the alignment system ALG, or to confirm the position and image quality of the pattern image projected from the projection unit PLU.
- a calibration reference unit CU is provided at the -X direction end on the substrate holder 4B.
- the number of modules may be less than or more than nine.
- three rows of exposure modules are arranged in the X-axis direction, but the number of rows of exposure modules arranged in the X-axis direction may be two or less, or four or more. .
- FIG. 2 is a diagram showing an arrangement example of the projection areas IAn of the DMD 10 projected onto the substrate P by the projection units PLU of the exposure module groups MU(A), MU(B), and MU(C).
- the coordinate system XYZ is set the same as in FIG.
- the exposure module group MU (A) in the first row, the exposure module group MU (B) in the second row, and the exposure module group MU (C in the third row) are spaced apart in the X-axis direction.
- ) is composed of nine modules arranged in the Y-axis direction.
- the exposure module group MU(A) consists of nine modules MU1 to MU9 arranged in the +Y direction
- the exposure module group MU(B) consists of nine modules MU10 to MU18 arranged in the -Y direction
- the exposure module group MU(C) is composed of nine modules MU19 to MU27 arranged in the +Y direction.
- the modules MU1 to MU27 all have the same configuration, and when the exposure module group MU(A) and the exposure module group MU(B) face each other in the X-axis direction, the exposure module group MU(B) and the exposure module
- the group MU (C) has a back-to-back relationship with respect to the X-axis direction.
- the center point of each of the projection areas IA1 to IA9 in the first row is located on a line k1 parallel to the Y axis
- the center point of each of the projection areas IA10 to IA18 in the second row is on a line k2 parallel to the Y axis
- the center point of each of the projection areas IA19 to IA27 in the third row is located on a line k3 parallel to the Y-axis.
- the distance between lines k1 and k2 in the X-axis direction is set to distance XL1
- the distance between lines k2 and k3 in the X-axis direction is set to distance XL2.
- the connecting portion between the -Y direction end of the projection area IA9 and the +Y direction end of the projection area IA10 is OLa
- the -Y direction end of the projection area IA10 and the +Y direction end of the projection area IA27 and OLb, and the joint portion between the +Y-direction end of the projection area IA8 and the -Y-direction end of the projection area IA27 is OLc.
- the orthogonal coordinate system XYZ is set the same as in FIGS.
- the coordinate system X'Y' in the projection areas IA8, IA9, IA10, IA27 (and all other projection areas IAn) is It is set to be inclined by an angle ⁇ k with respect to the X-axis and Y-axis (lines k1 to k3) of the orthogonal coordinate system XYZ. That is, the entire DMD 10 is tilted by an angle ⁇ k in the XY plane so that the two-dimensional array of many micromirrors of the DMD 10 is in the X'Y' coordinate system.
- a circular area encompassing each of the projection areas IA8, IA9, IA10, IA27 (and all other projection areas IAn as well) in FIG. 3 represents the circular image field PLf' of the projection unit PLU.
- the projection image of the micromirrors arranged obliquely (angle ⁇ k) at the end of the projection area IA10 in the ⁇ Y′ direction and the projection image of the micromirrors arranged obliquely (angle ⁇ k) at the end of the projection area IA27 in the +Y′ direction It is set so that the projected images of the aligned micromirrors overlap.
- the projection image of the micromirrors arranged obliquely (angle ⁇ k) at the end of the projection area IA8 in the +Y′ direction and the oblique (angle ⁇ k) end of the projection area IA27 in the ⁇ Y′ direction ) are set so as to overlap the projection images of the micromirrors arranged in the plane.
- FIG. 4 is an optical view of the specific configuration of the module MU18 in the exposure module group MU(B) and the module MU19 in the exposure module group MU(C) shown in FIGS. 1 and 2 in the XZ plane. It is a layout diagram.
- the orthogonal coordinate system XYZ in FIG. 4 is set the same as the orthogonal coordinate system XYZ in FIGS.
- the module MU18 is shifted in the +Y direction with respect to the module MU19 by a constant interval and is installed in a back-to-back relationship.
- the optical fiber unit FBU shown in FIG. 1 is composed of 27 optical fiber bundles FB1 to FB27 corresponding to the 27 modules MU1 to MU27 shown in FIG.
- the illumination unit ILU of the module MU18 functions as a mirror 100 that reflects the illumination light ILm traveling in the -Z direction from the output end of the optical fiber bundle FB18, a mirror 102 that reflects the illumination light ILm from the mirror 100 in the -Z direction, and a collimator lens.
- Mirror 102, input lens system 104, optical integrator 108, condenser lens system 110, and tilt mirror 112 are arranged along optical axis AXc parallel to the Z axis.
- the optical fiber bundle FB18 is configured by bundling one optical fiber line or a plurality of optical fiber lines.
- the illumination light ILm emitted from the output end of the optical fiber bundle FB18 (each of the optical fiber lines) is set to a numerical aperture (NA, also called divergence angle) so as to enter the input lens system 104 at the subsequent stage without being vignetted.
- NA numerical aperture
- the position of the front focal point of the input lens system 104 is designed to be the same as the position of the output end of the optical fiber bundle FB18.
- the position of the rear focal point of the input lens system 104 is such that the illumination light ILm from a single or a plurality of point light sources formed at the output end of the optical fiber bundle FB18 is superimposed on the incident surface side of the MFE lens 108A of the optical integrator 108. is set to let Therefore, the incident surface of the MFE lens 108A is Koehler-illuminated by the illumination light ILm from the exit end of the optical fiber bundle FB18.
- the geometric center point in the XY plane of the output end of the optical fiber bundle FB18 is positioned on the optical axis AXc, and the principal ray ( center line) is parallel (or coaxial) with the optical axis AXc.
- Illumination light ILm from input lens system 104 is attenuated by an arbitrary value in the range of 0% to 90% by illumination adjustment filter 106, and then passes through optical integrator 108 (MFE lens 108A, field lens, etc.). , enter the condenser lens system 110 .
- the MFE lens 108A is a two-dimensional arrangement of a large number of rectangular microlenses of several tens of ⁇ m square. ) is set to be almost similar to Also, the position of the front focal point of the condenser lens system 110 is set to be substantially the same as the position of the exit surface of the MFE lens 108A.
- each illumination light from a point light source formed on each exit side of a large number of microlenses of the MFE lens 108A is converted into a substantially parallel light beam by the condenser lens system 110, and after being reflected by the tilt mirror 112, , are superimposed on the DMD 10 to form a uniform illuminance distribution. Since a surface light source in which a large number of point light sources (condensing points) are two-dimensionally densely arranged is generated on the exit surface of the MFE lens 108A, the MFE lens 108A functions as a surface light source forming member.
- the optical axis AXc passing through the condenser lens system 110 and parallel to the Z-axis is bent by the tilt mirror 112 and reaches the DMD 10.
- AXb the neutral plane including the center point of each of the numerous micromirrors of DMD 10 is set parallel to the XY plane. Therefore, the angle formed by the normal to the neutral plane (parallel to the Z-axis) and the optical axis AXb is the incident angle ⁇ of the illumination light ILm with respect to the DMD 10 .
- the DMD 10 is attached to the underside of a mount portion 10M fixed to the support column of the illumination unit ILU.
- the mount section 10M is provided with a fine movement stage that combines a parallel link mechanism and an extendable piezo element as disclosed in, for example, International Publication No. 2006/120927. be done.
- FIG. 5A is a diagram schematically showing the DMD 10
- FIG. 5B is a diagram showing the DMD 10 when the power is off
- FIG. 5C is an explanation of mirrors in the ON state
- FIG. 5D is a diagram for explaining the mirror in the OFF state.
- mirrors in the ON state are indicated by hatching.
- the DMD 10 has a plurality of micromirrors Ms whose reflection angle can be changed and controlled.
- the DMD 10 is of a roll-and-pitch drive type that switches between the ON state and the OFF state by tilting the micromirrors Ms in the roll direction and the pitch direction.
- each micromirror Ms when the power is off, the reflecting surface of each micromirror Ms is set parallel to the X'Y' plane.
- the array pitch of the micromirrors Ms in the X' direction is Pdx ([mu]m), and the array pitch in the Y' direction is Pdy ([mu]m).
- FIG. 5C shows a case where only the central micromirror Ms is in the ON state and the other micromirrors Ms are in the neutral state (neither ON nor OFF state). Each micromirror Ms is turned off by tilting around the X' axis.
- FIG. 5D shows a case where only the central micromirror Ms is in the OFF state and the other micromirrors Ms are in the neutral state.
- the ON-state micromirror Ms is arranged on the X'Y' plane so that the illumination light applied to the ON-state micromirror Ms is reflected in the X-axis direction of the XZ plane. is driven to tilt at a predetermined angle from Further, the micromirror Ms in the OFF state is driven to be tilted at a predetermined angle from the X'Y' plane so that the illumination light applied to the micromirror Ms in the OFF state is reflected in the Y-axis direction in the YZ plane. be.
- the DMD 10 generates an exposure pattern by switching the ON state and OFF state of each micromirror Ms.
- Illumination light reflected by the mirror in the OFF state is absorbed by a light absorber (not shown).
- the DMD 10 has been described as an example of a spatial light modulator, the DMD 10 has been described as a reflective type that reflects laser light. A diffractive type may also be used.
- a spatial light modulator can spatially and temporally modulate laser light.
- the illumination light ILm irradiated to the ON-state micromirror Ms of the micromirrors Ms of the DMD 10 is reflected in the X-axis direction in the XZ plane toward the projection unit PLU.
- the illumination light ILm irradiated to the OFF-state micromirror Ms among the micromirrors Ms of the DMD 10 is reflected in the Y-axis direction in the YZ plane so as not to be directed toward the projection unit PLU.
- a movable shutter 114 for shielding reflected light from the DMD 10 during a non-exposure period is detachably provided in the optical path between the DMD 10 and the projection unit PLU.
- the movable shutter 114 is rotated to an angular position retracted from the optical path during the exposure period, as illustrated on the module MU19 side, and inserted obliquely into the optical path during the non-exposure period, as illustrated on the module MU18 side. is rotated to the desired angular position.
- a reflecting surface is formed on the DMD 10 side of the movable shutter 114 , and the light from the DMD 10 reflected there is applied to the light absorber 117 .
- the light absorber 117 absorbs light energy in the ultraviolet wavelength range (wavelength of 400 nm or less) without re-reflection and converts it into heat energy. Therefore, the light absorber 117 is also provided with a heat dissipation mechanism (radiating fins or a cooling mechanism).
- a heat dissipation mechanism radiatating fins or a cooling mechanism.
- the reflected light from the micromirror Ms of the DMD 10 which is in the OFF state during the exposure period, is reflected in the Y-axis direction with respect to the optical path between the DMD 10 and the projection unit PLU, as described above. It is absorbed by a similar light absorber (not shown in FIG. 4) placed (perpendicular to the page of FIG. 4).
- the projection unit PLU attached to the lower side of the optical surface plate 5 is a double-telecentric combination composed of a first lens system 116 and a second lens system 118 arranged along an optical axis AXa parallel to the Z axis. It is configured as an image projection lens system.
- the first lens system 116 and the second lens system 118 are translated by a fine actuator in a direction along the Z-axis (optical axis AXa) with respect to a support column fixed to the lower side of the optical surface plate 5.
- the projection magnification Mp is set to about 1/6, taking into account the tilt angle ⁇ k in the XY plane.
- An imaging projection lens system formed by lens systems 116 and 118 inverts/inverts the reduced image of the entire mirror surface of DMD 10 and forms an image on projection area IA 18 (IAn) on substrate P.
- the first lens system 116 of the projection unit PLU can be finely moved in the direction of the optical axis AXa by an actuator in order to finely adjust the projection magnification Mp (approximately ⁇ several tens of ppm), and the second lens system 118 is for high-speed focus adjustment. Therefore, the actuator can be finely moved in the direction of the optical axis AXa. Further, a plurality of oblique incident light type focus sensors 120 are provided below the optical surface plate 5 in order to measure the positional change of the surface of the substrate P in the Z-axis direction with submicron accuracy.
- the projection area IAn must be tilted by the angle ⁇ k in the XY plane as described above with reference to FIG. (at least the optical path portion of the mirrors 102 to 112 along the optical axis AXc) are arranged so as to be inclined by an angle ⁇ k in the XY plane as a whole.
- FIG. 6 is a diagram schematically showing a state in which the DMD 10 and the projection unit PLU are tilted by an angle ⁇ k in the XY plane.
- the orthogonal coordinate system XYZ is the same as the coordinate system XYZ of each of FIGS. Same as Y'.
- the circle enclosing the DMD 10 is the image field PLf on the object plane side of the projection unit PLU, and the optical axis AXa is positioned at its center.
- the optical axis AXb which is the optical axis AXc that has passed through the condenser lens system 110 of the illumination unit ILU and is bent by the tilting mirror 112, is tilted at an angle ⁇ k from the line Lu parallel to the X axis when viewed in the XY plane. placed.
- FIG. 7 the imaging state of the micromirrors Ms of the DMD 10 by the projection unit PLU (imaging projection lens system) will be described in detail.
- the orthogonal coordinate system X'Y'Z in FIG. 7 is the same as the coordinate system X'Y'Z shown in FIGS. 3 and 6.
- the optical path of Illumination light ILm from condenser lens system 110 travels along optical axis AXc, is totally reflected by inclined mirror 112, and reaches the mirror surface of DMD 10 along optical axis AXb.
- Msc be the micromirror Ms located in the center of the DMD 10
- Msa be the micromirrors Ms located in the periphery
- these micromirrors Msc and Msa are in the ON state.
- the tilt angle of the micromirror Ms in the ON state is, for example, a standard value of 17.5° with respect to the X'Y' plane (XY plane), the reflected light Sc from each of the micromirrors Msc and Msa,
- the incident angle (the angle of the optical axis AXb from the optical axis AXa) ⁇ of the illumination light ILm irradiated to the DMD 10 is 35.0°.
- the principal ray Lc of the reflected light Sc from the micromirror Msc is coaxial with the optical axis AXa, and the principal ray La of the reflected light Sa from the micromirror Msa is parallel to the optical axis AXa. It enters the projection unit PLU with a numerical aperture (NA).
- a reduced image ic of the micromirror Msc reduced by the projection magnification Mp of the projection unit PLU is telecentrically formed on the substrate P at the position of the optical axis AXa by the reflected light Sc.
- a reduced image ia of the micromirror Msa reduced by the projection magnification Mp of the projection unit PLU is telecentrically formed on the substrate P at a position away from the reduced image ic in the +X′ direction.
- the first lens system 116 of the projection unit PLU is composed of two lens groups G1, G2, and the second lens system 118 is composed of three lens groups G3, G4, G5.
- An exit pupil (simply called a pupil) Ep is set between the lens group G3 and the lens group G4 of the second lens system 118 .
- a light source image of the illumination light ILm (a set of many point light sources formed on the exit surface side of the MFE lens 108A) is formed to constitute Koehler illumination.
- the pupil Ep is also called the aperture of the projection unit PLU, and the size (diameter) of the aperture is one factor that defines the resolving power of the projection unit PLU.
- Specularly reflected light from the ON-state micromirror Ms of the DMD 10 is set so as to pass through without being blocked by the maximum aperture (diameter) of the pupil Ep.
- the numerical aperture NAo of the projection unit PLU (lens groups G1 to G5) on the object plane (DMD10) side is expressed by the product of the projection magnification Mp and the numerical aperture NAi. NAi/6.
- the illumination light ILm irradiated onto the entire mirror surface of the DMD 10 has a uniform illuminance distribution (for example, intensity unevenness within ⁇ 1%) due to the action of the optical integrator 108 .
- the exit end side of the MFE lens 108A and the plane of the pupil Ep of the projection unit PLU are set in an optically conjugate relationship by the condenser lens system 110 and the lens groups G1 to G3 of the projection unit PLU.
- FIG. 8 is a diagram showing a schematic configuration of the alignment device 60 provided in the calibration reference unit CU attached to the end of the substrate holder 4B of the exposure apparatus EX.
- the alignment device 60 includes a reference mark 60a, a two-dimensional imaging device 60e, and the like. Alignment device 60 is used to measure and calibrate the positions of various modules, and is also used to calibrate alignment system ALG.
- the positions of the modules MU1 to MU27 are measured by projecting the calibration pattern image onto the reference mark 60a of the alignment device 60 by the projection unit PLU, and measuring the relative position between the reference mark 60a and the calibration pattern image. It is done by
- alignment system ALG can be calibrated by measuring reference mark 60a of alignment device 60 with alignment system ALG. That is, the position of alignment system ALG can be determined by measuring reference mark 60a of alignment device 60 with alignment system ALG. Furthermore, using reference mark 60a, it is possible to determine the relative positions of alignment system ALG and modules MU1 to MU27.
- Alignment system ALG can also measure the position of the alignment mark on substrate P placed on substrate holder 4B with reference to reference mark 60a of alignment device 60 .
- FIG. 9 is a diagram of the substrate holder 4B viewed from the +Z direction.
- FIG. 10 is a diagram showing a schematic configuration of inspection devices 400a to 400i provided in an inspection unit IU provided at the end of the substrate holder 4B in the +X direction.
- the inspection unit IU is provided on the opposite side of the substrate holder 4B from the calibration reference unit CU in the X-axis direction.
- a plurality of inspection devices 400a to 400i are arranged in a direction (Y-axis direction) orthogonal to the scanning exposure direction of the substrate P (X-axis direction).
- the inspection devices 400a to 400i are devices for inspecting whether or not the DMDs 10 of the modules MU1 to MU27 can generate pattern light corresponding to pattern data (drawing data).
- it is a device for inspecting whether or not the DMD 10 has a defective element (defective micromirror) that cannot be driven according to drawing data.
- the defective element is an element that cannot be driven according to drawing data because the micromirror Ms of the DMD 10 is stuck in the ON state or stuck in the OFF state, for example.
- the inspection devices 400a to 400i are provided, for example, so as to correspond to the modules MU1 to MU9 included in the exposure module group MU(A). That is, the modules are arranged such that the pitch P1 between the centers of adjacent modules in the Y-axis direction is equal to the pitch P2 between the centers of adjacent inspection devices in the Y-axis direction.
- inspection apparatuses 400a to 400i will be referred to as inspection apparatus 400 unless otherwise specified.
- the inspection device 400 may be provided so as to correspond to the modules MU1 to MU27. That is, 27 inspection devices 400 may be arranged in the inspection unit IU.
- the number of inspection devices 400 is not limited to the number shown in FIG. 9, and may be eight or less, or may be ten or more.
- FIG. 10(A) it includes a magnifying imaging system 401 that magnifies the pattern image projected by the projection unit PLU, and a CCD or CMOS imaging device 402 that captures the magnified image.
- the object microwavemirror Ms
- the inspection apparatus 400 may have a CCD or CMOS image sensor 402 that directly captures the pattern image projected by the projection unit PLU.
- the imaging element 402 is provided in the same plane as the substrate P or the substrate holder 4B.
- the imaging element 402 is tilted within the XY plane by an angle ( ⁇ k: see FIG. 6) by which the DMD 10 is tilted within the XY plane. It should be noted that the imaging device 402 does not have to be tilted in the XY plane.
- the DMD 10 when checking whether or not the DMD 10 has a defective element using an imaging device, it is conceivable to associate the pixels of the imaging device with the elements (micromirrors) Ms of the DMD 10 on a one-to-one basis. In this case, the image of the pattern generated by the DMD 10 is projected onto each pixel of the image pickup device, and the projected image is picked up. can be easily checked for defects.
- the pattern image generated by the DMD 10 is usually reduced and projected onto the substrate P by the projection unit PLU.
- the image of the pattern produced by DMD 10 is demagnified by projection unit PLU, eg, about 1/6.
- the image of the pattern projected after being reduced by the projection unit PLU is enlarged by the enlargement imaging system 401 to the reciprocal of the reduction magnification.
- the magnifying imaging system 401 becomes large, which leads to an increase in the size of the inspection apparatus 400 .
- an imaging element having at least the same number of pixels as the number of pixels of the DMD 10 is used.
- the enlargement magnification of the enlargement imaging system 401 is set so that each pixel IPX of the image sensor 402 includes pattern images projected from the plurality of elements Ms of the DMD 10 .
- one pixel IPX1 (broken line) of the image pickup device 402 is made to include a plurality of elements (micromirrors) Ms (solid lines) of the DMD 10 .
- the projected pattern image is enlarged so that the pattern image generated by the four elements Ms of the DMD 10 is projected onto the corresponding one pixel IPX1 of the imaging element 402 .
- the number of pixels required by the image sensor 402 can be reduced (for example, 1/4 of the case where one pixel of the pattern image and the pixel of the image sensor correspond to each other at 1:1). can be made smaller. Moreover, since the magnification of the magnifying imaging system 401 can be reduced, the size of the magnifying imaging system 401 can be reduced.
- the number of elements of the DMD 10 included in each pixel of the imaging device 402 is determined by the magnification of the magnifying imaging system 401, the minimum pitch between pixels of the image of the pattern projected onto the substrate P, and the pixels of the imaging device 402. It is determined by the relationship between the arrangement pitch of .
- FIG. 11 shows the function of the inspection control apparatus 300 for determining whether or not there is a defective element in the DMD 10 of each of the modules MU1 to MU27 based on the input from the inspection apparatus 400, and for specifying the module of the DMD 10 in which the defective element exists. It is a block diagram.
- the inspection control device 300 includes an inspection pattern output section 310, a determination section 301, and a stage driving section 305.
- the inspection pattern output unit 310 outputs inspection pattern data ID1 to ID27 to the modules MU1 to MU27, respectively.
- the DMD 10 of each of the modules MU1-MU27 generates a pattern based on the inspection pattern data ID1-ID27.
- the determination unit 301 determines whether or not there is a defective element in the DMD 10 of each of the modules MU1 to MU27 based on the data input from the inspection apparatuses 400a to 400i, and identifies the module of the DMD 10 in which the defective element exists.
- the stage drive unit 305 drives the XY stage 4A so that the modules MU1 to MU27 to be inspected are positioned above the inspection devices 400a to 400i.
- FIG. 12 is a flowchart showing an example of processing executed by the inspection control device 300. As shown in FIG.
- the stage driving section 305 drives the XY stage 4A to position the inspection devices 400a to 400i under the respective MU1 to MU9 (step S11).
- FIG. 13 is a flowchart showing details of the inspection process. The processing in FIG. 13 is performed for each of the modules MU1 to MU9, but the module MU1 will be described below as an example.
- the test pattern output unit 310 outputs the pattern data ID1 of the first test pattern to the module MU1, and the module MU1 outputs the pattern generated by the DMD 10 based on the pattern data ID1 (the first pattern). ) is projected (step S131).
- FIG. 14A is a diagram showing an image of the first inspection pattern projected onto the imaging element 402 when the DMD 10 has no defective elements
- FIG. FIG. 4 is a diagram showing an image of the first inspection pattern projected onto one pixel IPX1 of the imaging device 402;
- the first test pattern is a staggered pattern obtained by alternately turning ON and OFF the micromirrors Ms of the DMD 10 .
- black portions indicate the OFF state.
- the determination unit 301 measures the illuminance of the projected first pattern for each pixel IPX of the imaging device 402 of the inspection device 400a (step S132). Let the illuminance acquired in step S132 be the first illuminance.
- the inspection pattern output unit 310 outputs the pattern data ID1 of the second inspection pattern to the module MU1, and the module MU1 outputs the image of the pattern (referred to as the second pattern) generated by the DMD 10 based on the pattern data ID1. Project (step S133).
- FIG. 14(C) is a diagram showing an image of the second inspection pattern projected onto the imaging device 402 when the DMD 10 has no defective elements.
- FIG. 10 is a diagram showing an image of a second inspection pattern projected onto one pixel IPX1 of the imaging device 402;
- the second inspection pattern is a staggered pattern obtained by reversing the ON and OFF states of the micromirrors Ms of the DMD 10 from those of the first inspection pattern.
- the determination unit 301 measures the illuminance of the projected image of the second pattern for each pixel IPX of the imaging device 402 of the inspection device 400a (step S134).
- the illuminance acquired in step S134 be the second illuminance.
- the first illuminance and the second illuminance include the luminance value and gradation value of the imaging element.
- the determination unit 301 compares the first illuminance and the second illuminance (step S135).
- the number of pixels in the ON state in the first inspection pattern is equal to the number of pixels in the ON state in the second inspection pattern, and the number of pixels in the OFF state in the first inspection pattern is also in the OFF state in the second inspection pattern. Equal to a certain number of pixels. Therefore, if each element of the DMD 10 corresponding to each pixel IPX of the image sensor 402 does not include a defective element, the difference between the first illumination and the second illumination should be approximately 0 at each pixel IPX of the image sensor 402. is. Therefore, the determination unit 301 determines whether the difference between the first illuminance and the second illuminance is within a predetermined range (for example, within ⁇ 1%) for each pixel IPX of the image sensor 402 (step S136).
- the determination unit 301 determines whether the DMD 10 of the module MU1 has a defective element. It is determined that there is no (step S137).
- the determination unit 301 determines that the DMD 10 of the module MU1 is a defective element. (step S138).
- the determination unit 301 stores the determination result in a storage unit (not shown) such as a non-volatile memory (step S139).
- the processing of FIG. 13 is also performed for the other modules MU2 to MU9 included in the exposure module group MU(A), and the determination result of whether or not the DMD 10 of each of the modules MU1 to MU9 has a defective element is stored in the storage unit. stored in
- step S15 determines whether or not there is an exposure module that has not yet been inspected. For example, when the inspection of the modules MU1 to MU9 included in the exposure module group MU(A) is completed, the inspection of the exposure module groups MU(B) and MU(C) is not completed, so the determination in step S15 is YES. becomes.
- step S15 If the determination in step S15 is YES, the process returns to step S11. Then, the stage drive unit 305 drives the XY stage 4A to position the inspection devices 400a to 400i below the modules MU18 to MU10 included in the exposure module group MU(B).
- step S13 the inspection process described above is executed for the modules MU10 to MU18.
- step S15 When the inspection of the exposure module group MU(B) is completed, the exposure module group MU(C) has not yet been inspected (step S15/YES), so the process returns to step S11.
- the stage drive unit 305 drives the XY stage 4A to position the inspection devices 400a to 400i below the modules MU19 to MU27 included in the exposure module group MU(C) (step S11).
- step S13 the exposure module group MU(C) is inspected (step S13), and when all the exposure module groups MU(A) to MU(C) have been inspected, the determination in step S15 becomes NO.
- the determination unit 301 outputs the determination result stored in the storage unit (step S17), and ends the processing in FIG. At this time, the determination unit 301 may, for example, display the determination result on a display device such as a liquid crystal display, or may print the determination result on a printer. For example, the determination unit 301 outputs whether or not the DMD 10 has a defective element for each of the modules MU1 to MU27.
- the determination unit 301 determines whether the DMD 10 having the defective element has the pattern based on the recipe of the pattern to be exposed on the substrate P and the position of the DMD 10 having the defective element.
- the degree of influence on exposure results may be calculated.
- the determination unit 301 may output the module including the DMD 10 having the defective element and the calculated degree of influence.
- the determination unit 301 may output the degree of influence and allow the operator to select whether to proceed with the exposure processing as it is. For example, the operator can select whether to stop the exposure process, perform the exposure process using a normal DMD 10 with no defective element, or continue the exposure process as it is because the effect on the exposure result is small.
- the determination unit 301 may simulate the exposure result based on the recipe information of the pattern to be exposed on the substrate P and the position of the DMD 10 having the defective element, and output the simulation result. good. This allows the operator to more easily determine whether or not to continue exposure processing.
- a threshold for the number of defective elements and a threshold for the number of defective elements that affect the scanning exposure pattern are determined in advance, and after the inspection, it is possible to select whether or not to continue the exposure process based on the obtained inspection result. It is also possible to
- the determination unit 301 determines that there are multiple regions including defective elements in the DMD 10. You may make it output the said result.
- the exposure apparatus EX includes the DMD 10 that generates a pattern corresponding to drawing data, the illumination unit ILU that irradiates the DMD 10 with illumination light, and the pattern generated by the DMD 10.
- a projection unit PLU that projects a reduced pattern image onto the substrate P placed on the substrate holder 4B, an inspection device 400 that detects the projected pattern image, and a detection result of the inspection device 400. and a judgment unit 301 for judging whether or not the DMD 10 has a defective element. Thereby, it is possible to inspect whether or not the DMD 10 has a defective element within the exposure apparatus EX.
- the determination unit 301 detects the detection result of the image of the first pattern projected when the DMD 10 generates the first inspection pattern and the image projected when the second inspection pattern is generated by the DMD 10 . Then, it is determined whether the DMD 10 has a defective element based on the detection result of the image of the second pattern.
- the inspection apparatus 400 also detects the illuminance of the first pattern image and the illuminance of the second pattern image.
- the first test pattern is a zigzag pattern obtained by alternately turning ON and OFF pixels of the DMD 10
- the second test pattern is the ON state and the OFF state of the first test pattern. This is an inverted houndstooth pattern. This makes it possible to determine whether the DMD 10 has defective elements by comparing the illuminance without inspecting each element of the DMD 10 .
- the inspection apparatus 400 generates a and a magnifying imaging system 401 that magnifies the projected pattern image so that the projected pattern image is projected onto the corresponding pixels IPX1 to IPX4 of the imaging device 402 .
- each of the pixels IPX1 to IPX4 of the image sensor 402 receives light from the plurality of elements Ms of the DMD10.
- the exposure apparatus EX includes a DMD 10, an illumination unit ILU, and a projection unit PLU. Equipped with a plurality of arrayed modules (for example, MU1 to MU9), the inspection apparatus 400 is arranged in plurality in the Y-axis direction (inspection apparatuses 400a to 400i) so as to correspond to the plurality of modules MU1 to MU9. As a result, the inspection can be performed in a short period of time as compared with the case where the plurality of modules MU1 to MU9 are inspected by one inspection apparatus 400.
- the number of elements Ms of the DMD 10 corresponding to one pixel IPX of the image sensor 402 may be 5 ⁇ 5 or more, or may be 3 ⁇ 3, and corresponds to one pixel IPX of the image sensor 402.
- the number of elements Ms of the DMD 10 does not have to be integer ⁇ integer, but may be 1.5 ⁇ 1.5.
- the inspection devices 400a to 400i may also be used as the alignment device 60 provided in the calibration reference unit CU. That is, the imaging device 402 of the inspection device 400 may be used as the two-dimensional imaging device 60 e of the alignment device 60 .
- the inspection apparatus 400 may become large, the image sensor 402 having pixels IPX in 1:1 correspondence with the elements Ms of the DMD 10 is used to capture the projected pattern image. Then, whether or not the DMD 10 has a defective element may be determined based on the captured image. Moreover, when the DMD 10 has a defective element, the position of the defective element may be specified based on the captured image.
- the test pattern is exposed on the substrate P, and the substrate P exposed to the test pattern is measured by a measurement apparatus (microscope). and identify DMDs 10 that have defective elements.
- a measurement apparatus microscope
- a photochromic element may be arranged instead of the inspection apparatus 400, a test pattern may be exposed on the photochromic element, and the exposure result may be observed and measured by the alignment system ALG to identify the defective element.
- the microscope of the inspection apparatus used in the inspection process of the exposed substrate P may be used.
- the pattern images generated in each of the plurality of regions are projected onto the corresponding pixels IPX of the image sensor 402.
- the magnifying imaging system 401 is used, but the magnifying imaging system 401 may be omitted as shown in FIG. 8B.
- the imaging element 402 is arranged on the substrate holder 4B so that its light receiving surface is positioned substantially at the same position as the best focus plane (best imaging plane) of the projection unit PLU in the Z-axis direction.
- the pattern image reduced by the projection unit PLU is projected onto the imaging device 402 .
- the first illuminance of the image of the first pattern projected when the DMD 10 is caused to generate the first inspection pattern and the second pattern projected when the second inspection pattern is generated by the DMD 10 is compared with the second illuminance of the image of the entire image sensor 402, and it is determined whether or not the difference between the first illuminance and the second illuminance is within a predetermined range. can determine whether Moreover, since the magnifying imaging system 401 can be omitted, the inspection apparatus 400 can be further miniaturized.
- an illuminance sensor may be used in place of the imaging device 402 .
- the DMD 10 has a defective element is specified, but the position of the defective element is not specified.
- the location of the defective element can be identified as follows.
- FIG. 15A is a diagram showing the elements (Ms) PX1 to PX16 included in the area of the DMD 10 corresponding to one pixel IPX1 of the imaging element 402 (first state).
- the element PX6 is assumed to be a defective element.
- the processing described with reference to FIG. 13 although it is known that a defective element exists within the area of the DMD 10 corresponding to the pixel IPX1 of the image sensor 402, which pixel among the elements PX1 to PX16 included in that area is defective? It is not possible to identify whether it is a defective element.
- a block is defined that includes a plurality of elements adjacent to each other in the X-axis direction and the Y-axis direction. Elements included in each block are included in one pixel IPX1 used in the first state (second state). The number of elements included in each block is less than the number of elements included in the pixel IPX1. This is achieved by changing the magnifying power of the magnifying imaging system 401 to change the elements included in one pixel IPX1 between the first state and the second state in the same pixel.
- block BLK1 including elements PX1, PX2, PX5 and PX6, block BLK2 including elements PX2, PX3, PX6 and PX7, block BLK3 including elements PX3, PX4, PX7 and PX8 Define A block BLK4 including elements PX5, PX6, PX9 and PX10, a block BLK5 including elements PX6, PX7, PX10 and PX11, and a block BLK6 including elements PX7, PX8, PX11 and PX12 are defined.
- block BLK7 including elements PX9, PX10, PX13 and PX14
- block BLK8 including elements PX10, PX11, PX14 and PX15
- block BLK9 including elements PX11, PX12, PX15 and PX16 are defined. Note that in FIGS. 15A and 15B, the elements are drawn apart from each other in order to make the drawings easier to see.
- the presence or absence of a defective element is determined by comparing the second illuminance of the image of the second pattern thus obtained.
- the block BLK1, the block BLK2, the block BLK4, and the block BLK5 include the defective element PX6, it is determined that the defective element exists in the block BLK1, the block BLK2, the block BLK4, and the block BLK5. be done.
- the element PX6 is common to the block BLK1, the block BLK2, the block BLK4, and the block BLK5, it can be determined that the element PX6 is a defective element.
- a plurality of elements included in a region of the DMD 10 corresponding to one pixel of the imaging element 402 is divided into a plurality of blocks in which adjacent blocks in the X-axis direction and the Y-axis direction include common elements.
- the determining unit 301 may determine the influence of the defective element on the exposure result of the pattern in consideration of the position of the defective element, and output the result.
- the present invention is not limited to this, and various modifications can be made without departing from the spirit of the present invention.
- the element Ms of the DMD 10 may be directly observed by the alignment device 60 by switching ON/OFF the part considered to be the defective element. In this case, it is desirable to observe with an optical magnification that makes the pixels of the alignment device 60 larger than the elements Ms of the DMD 10 . Further, in this embodiment, an example of a houndstooth check pattern in which ON/OFF is switched between adjacent elements Ms is shown.
- the inspection pattern is not limited to the houndstooth pattern.
- the two inspection patterns may be patterns that are not staggered. Although not staggered, all 16 elements in the pixel IPX1 are turned on or off once by the first inspection pattern or the second inspection pattern. By using such a pattern, it is possible to identify defective elements.
- the inspection pattern of the present invention is not limited to this, and can be appropriately designed without departing from the gist of the present invention.
- defective elements may be identified as follows.
- the first inspection pattern is a pattern that turns on a specific element included in the pixel IPX
- the second inspection pattern is a pattern that turns off all the elements included in the pixel IPX
- the first inspection pattern and the inspection result of the second inspection pattern By performing this operation for all the elements included in the pixel IPX, it is possible to identify the presence or absence of defective elements.
- a spatial light modulator that generates a pattern corresponding to drawing data, an illumination unit that irradiates the spatial light modulator with illumination light, and an image of the pattern generated by the spatial light modulator on a substrate.
- a projection unit for projecting a reduced image onto a substrate placed on a holder; a detection unit for detecting the projected image of the pattern;
- a determination unit that determines whether or not it has an element; an exposure apparatus.
- the determination unit transmits a detection result of a first pattern image projected when a first inspection pattern is generated by the spatial light modulator and a second inspection pattern to the spatial light modulator.
- the exposure apparatus according to supplementary note 1, wherein whether or not the spatial light modulator has a defective element is determined based on a detection result of the second pattern image projected when generated.
- the exposure apparatus according to Supplementary note 2, wherein the detection unit detects the illuminance of the first pattern image and the illuminance of the second pattern image.
- the first test pattern is a zigzag pattern obtained by alternately turning ON and OFF elements of the spatial light modulator, and the second test pattern is the 3.
- the exposure apparatus according to appendix 2 or 3, wherein the pattern is a zigzag pattern in which the ON state and the OFF state of the first inspection pattern are reversed.
- Appendix 6 The exposure apparatus according to any one of appendices 1 to 5, wherein the detection unit is installed in the substrate holder.
- the detection unit is configured such that the image of the pattern generated in each of the plurality of regions is the above-mentioned 7.
- the detection unit includes an imaging device that projects the projected image of the pattern without enlarging it.
- inspection methods including; (Appendix 12) A spatial light modulator that generates a pattern corresponding to drawing data, an illumination unit that irradiates the spatial light modulator with illumination light, and an image of the pattern generated by the spatial light modulator that is projected onto a substrate. a projection unit that projects onto a substrate placed on a holder, and an inspection method for inspecting the spatial light modulator, wherein the image of the pattern generated by the spatial light modulator is projected onto the an inspection comprising: exposing a substrate; and determining whether the spatial light modulator has defective elements by measuring the substrate exposed with the image of the pattern using a measurement device. Method.
- a spatial light modulator that generates a pattern corresponding to drawing data, an illumination unit that illuminates the spatial light modulator with illumination light, and an image of the pattern generated by the spatial light modulator are placed on a substrate holder.
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Abstract
Description
図1は、一実施形態に係る露光装置EXの外観構成の概要を示す斜視図である。露光装置EXは、空間光変調素子(SLM:Spatial Light Modulator)によって、空間内での強度分布が動的に変調される露光光を被露光基板に結像投影する装置である。空間光変調器の例としては、液晶素子、デジタルマイクロミラーデバイス(DMD:Digital Micromirror Device)、磁気光学空間光変調器(MOSLM:Magneto Optic Spatial Light Modulator)等が挙げられる。本実施形態に係る露光装置EXは、空間光変調器としてDMD10を備えるが、他の空間光変調器を備えていてもよい。
図4は、図1、図2に示した露光モジュール群MU(B)中のモジュールMU18と、露光モジュール群MU(C)中のモジュールMU19との具体的な構成をXZ面内で見た光学配置図である。図4の直交座標系XYZは図1~図3の直交座標系XYZと同じに設定される。また、図2に示した各モジュールのXY面内での配置から明らかなように、モジュールMU18はモジュールMU19に対して+Y方向に一定間隔だけずらされると共に、互いに背中合わせの関係で設置されている。モジュールMU18内の各光学部材とモジュールMU19内の各光学部材は、それぞれ同じ材料で同じに構成されるので、ここでは主にモジュールMU18の光学構成について詳細に説明する。なお、図1に示した光ファイバーユニットFBUは、図2に示した27個のモジュールMU1~MU27の各々に対応して、27本の光ファイバー束FB1~FB27で構成される。
図5(A)は、DMD10を概略的に示す図であり、図5(B)は、電源がOFFの場合のDMD10を示す図であり、図5(C)は、ON状態のミラーについて説明するための図であり、図5(D)は、OFF状態のミラーについて説明するための図である。なお、図5(A)~図5(D)において、ON状態にあるミラーをハッチングで示している。
光学定盤5の下側に取り付けられた投影ユニットPLUは、Z軸と平行な光軸AXaに沿って配置される第1レンズ系116と第2レンズ系118とで構成される両側テレセントリックな結像投影レンズ系として構成される。第1レンズ系116と第2レンズ系118は、それぞれ光学定盤5の下側に固設される支持コラムに対して、Z軸(光軸AXa)に沿った方向に微動アクチュエータで並進移動するように構成される。第1レンズ系116と第2レンズ系118による結像投影レンズ系の投影倍率Mpは、DMD10上のマイクロミラーの配列ピッチPdと、基板P上の投影領域IAn(n=1~27)内に投影されるパターン像の最小線幅(最小画素寸法)Pgとの関係で決められる。
次に、図7を参照して、投影ユニットPLU(結像投影レンズ系)によるDMD10のマイクロミラーMsの結像状態を詳細に説明する。図7の直交座標系X’Y’Zは、先の図3、図6に示した座標系X’Y’Zと同じであり、図7では照明ユニットILUのコンデンサーレンズ系110から基板Pまでの光路を図示する。コンデンサーレンズ系110からの照明光ILmは、光軸AXcに沿って進み、傾斜ミラー112で全反射されて光軸AXbに沿ってDMD10のミラー面に達する。ここで、DMD10の中心に位置するマイクロミラーMsをMsc、周辺に位置するマイクロミラーMsをMsaとし、それらのマイクロミラーMsc、MsaがON状態であるとする。
図8は、露光装置EXの基板ホルダ4B上の端部に付設された較正用基準部CUに設けられるアライメント装置60の概略構成を示す図である。アライメント装置60は、基準マーク60a、及び二次元撮像素子60e等を備える。アライメント装置60は、各種モジュールの位置の計測及び較正のために使用され、アライメント系ALGの較正にも用いられる。
次に、検査部IUの構成について説明する。図9は、基板ホルダ4Bを+Z方向から見た図である。また、図10は、基板ホルダ4Bの+X方向の端部に設けられた検査部IUに設けられる検査装置400a~400iの概略構成を示す図である。
図11は、検査装置400からの入力に基づいて、各モジュールMU1~MU27それぞれのDMD10に欠陥素子が存在するか否か、及び欠陥素子が存在するDMD10のモジュールを特定する検査制御装置300の機能ブロック図である。
次に、検査制御装置300が実行する処理について説明する。図12は、検査制御装置300が実行する処理の一例を示すフローチャートである。
(付記1) 描画データに対応したパターンを生成する空間光変調器と、前記空間光変調器に照明光を照射する照明ユニットと、前記空間光変調器により生成された前記パターンの像を、基板ホルダ上に載置された基板上に縮小して投影する投影ユニットと、投影された前記パターンの像を検出する検出部と、前記検出部の検出結果に基づいて、前記空間光変調器が欠陥素子を有するか否かを判定する判定部と、
を備える露光装置。
(付記2) 前記判定部は、第1の検査パターンを前記空間光変調器に生成させたときに投影された第1パターン像の検出結果と、第2の検査パターンを前記空間光変調器に生成させたときに投影された第2パターン像の検出結果と、に基づいて、前記空間光変調器が欠陥素子を有するか否かを判定する、付記1に記載の露光装置。
(付記3) 前記検出部は、前記第1パターン像の照度と、前記第2パターン像の照度と、を検出する付記2に記載の露光装置。
(付記4) 前記第1の検査パターンは、前記空間光変調器の素子を交互にON状態とOFF状態とにすることにより得られる千鳥模様のパターンであり、前記第2の検査パターンは、前記第1の検査パターンの前記ON状態と前記OFF状態とを反転させた千鳥模様のパターンである、付記2または付記3に記載の露光装置。
(付記5) 前記空間光変調器と、前記照明ユニットと、前記投影ユニットと、をそれぞれ含み、前記基板の走査露光方向と直交する方向に配列された複数のモジュールを備え、前記検出部は、前記複数のモジュールと対応するように、前記走査露光方向と直交する方向に複数配列される、付記1から付記4のいずれか1つに記載の露光装置。
(付記6) 前記検出部は、前記基板ホルダに設置されている付記1から付記5のいずれか1つに記載の露光装置。
(付記7) 前記検出部は、複数画素を有する撮像素子と、前記空間光変調器の複数素子を複数の領域に分割した場合に、前記複数の領域それぞれにおいて生成されたパターンの像が、前記撮像素子の対応する画素に投影されるように、投影された前記パターンの像を拡大する拡大結像系と、を含む、付記1から付記6のいずれか1つに記載の露光装置。
(付記8) 前記検出部は、投影された前記パターンの像が拡大されずに投影される撮像素子を備える、付記1から付記6のいずれか1つに記載の露光装置。
(付記9) 前記撮像素子は、前記空間光変調器と、前記照明ユニットと、前記投影ユニットと、を含むモジュールの位置計測に用いられる、付記7または付記8に記載の露光装置。
(付記10) 前記検出部は、投影された前記パターンの像の照度を計測する照度センサを備える、付記7から付記9のいずれか1つに記載の露光装置。
(付記11) 描画データに対応したパターンを生成する空間光変調器と、前記空間光変調器に照明光を照射する照明ユニットと、前記空間光変調器により生成された前記パターンの像を、基板ホルダ上に載置された基板上に縮小して投影する投影ユニットと、を備える露光装置において、前記空間光変調器を検査する検査方法であって、投影された前記パターンの像を検出することと、前記パターンの像の検出結果に基づいて、前記空間光変調器が欠陥素子を有するか否かを判定することと、
を含む検査方法。
(付記12) 描画データに対応したパターンを生成する空間光変調器と、前記空間光変調器に照明光を照射する照明ユニットと、前記空間光変調器により生成された前記パターンの像を、基板ホルダ上に載置された基板上に投影する投影ユニットと、を備える露光装置において、前記空間光変調器を検査する検査方法であって、前記空間光変調器が生成した前記パターンの像を前記基板に露光することと、前記パターンの像が露光された前記基板を計測装置を用いて計測することにより、前記空間光変調器が欠陥素子を有するか否かを判定することと、を含む検査方法。
(付記13)
描画データに対応したパターンを生成する空間光変調器と、前記空間光変調器に照明光を照射する照明ユニットと、前記空間光変調器により生成された前記パターンの像を、基板ホルダ上に載置された基板上に投影する投影ユニットと、を備える露光装置において、前記空間光変調器を検査する検査方法であって、前記空間光変調器が生成した前記パターンの像をフォトクロミック素子に露光することと、前記パターンの像が露光された前記フォトクロミック素子を計測装置を用いて計測することにより、前記空間光変調器が欠陥素子を有するか否かを判定することと、を含む検査方法。
Ms マイクロミラー
300 検査制御装置
301 判定部
400、400a~400i 検査装置
401 拡大結像系
402 撮像素子
EX 露光装置
P 基板
ILU 照明ユニット
PLU 投影ユニット
Claims (21)
- 複数の素子を有する空間光変調器によって生成される描画データに応じたパターン光を物体に対して露光する露光装置であって、
前記空間光変調器に前記描画データを出力するデータ出力部と、
前記空間光変調器に照明光を照射する照明光学系と、
前記物体を保持する第1移動体と、
前記空間光変調器により生成された前記パターン光の像を、前記物体に投影する投影光学系と、
投影された前記パターン光の像を検出する検出部と、
前記検出部の検出結果に基づいて、前記空間光変調器が前記データ出力部から出力された前記描画データに応じたパターン光を生成可能か否かを判定する判定部と、
を備える露光装置。 - 前記判定部は、前記検出結果に基づいて、前記空間光変調器が前記データ出力部から出力された前記描画データに応じた駆動をすることができない欠陥素子を有するか否かを判定する、請求項1に記載の露光装置。
- 前記判定部は、前記複数の素子の少なくとも一部に第1の検査パターンを前記空間光変調器に生成させたときに投影された第1パターン像の検出結果と、前記複数の素子の少なくとも一部に第2の検査パターンを前記空間光変調器に生成させたときに投影された第2パターン像の検出結果と、に基づいて、前記欠陥素子の有無を判定する、
請求項2に記載の露光装置。 - 前記検出部は、前記第1パターン像の照度と、前記第2パターン像の照度と、を検出する、
請求項3に記載の露光装置。 - 前記第1の検査パターンは、前記複数の素子の少なくとも一部を交互にON状態とOFF状態とにすることにより得られるパターンであり、
前記第2の検査パターンは、前記第1の検査パターンの前記ON状態と前記OFF状態とを反転させることにより得られるパターンである、
請求項3または請求項4に記載の露光装置。 - 前記第1の検査パターンは、千鳥模様のパターンであり、
前記第2の検査パターンは、千鳥模様のパターンである、
請求項5に記載の露光装置。 - 前記空間光変調器と、前記照明光学系と、前記投影光学系と、をそれぞれ含み、前記物体の走査露光方向と直交する方向に配列された複数のモジュールを備え、
前記検出部は、前記複数のモジュールと対応するように、前記走査露光方向と直交する方向に複数配列される、
請求項1から請求項6のいずれか一項記載の露光装置。 - 前記検出部は、前記第1移動体と並進移動する、
請求項1から請求項7のいずれか一項記載の露光装置。 - 前記検出部は、前記第1移動体に設けられる、請求項8に記載の露光装置。
- 前記検出部は、複数の画素を有し、前記空間光変調器から投影される前記パターン光の像を撮像する撮像素子を有する、
請求項1から請求項9のいずれか一項記載の露光装置。 - 前記撮像素子は前記物体と略同一平面内に設けられる、
請求項10に記載の露光装置。 - 前記検出部は、前記撮像素子の上部に検出光学系を有し、
前記検出光学系は前記物体と略同一平面内に結像された前記像を拡大した拡大像を前記撮像素子に結像させる、
請求項10に記載の露光装置。 - 前記検出光学系は、前記撮像素子の1画素内に前記素子を2つ以上含むように前記パターン光を前記撮像素子に結像し、
前記判定部は、前記1画素内に含まれる前記素子の検出結果に基づいて、前記描画データに応じたパターン光を生成可能か否かを判定する、
請求項12に記載の露光装置。 - 前記検出光学系は、前記撮像素子の前記1画素内に前記素子を2つ以上含むように前記パターン光を前記撮像素子に結像する第1の状態と、前記第1の状態よりも前記1画素内に含まれる前記素子が少なくなる第2の状態とで、前記パターン光を前記撮像素子に結像し、
前記判定部は、前記第1の状態で計測した検出結果である第1結果と、前記第2の状態で計測した検出結果である第2結果とに基づいて、前記空間光変調器が前記データ出力部から出力された前記描画データに応じた駆動をすることができない欠陥素子を有するか否かを判定する、
請求項13に記載の露光装置。 - 前記空間光変調器と、前記照明光学系と、前記投影光学系とを有するモジュール部を備え、
前記検出部は、前記欠陥素子の検出に加え、前記モジュール部の位置計測に用いられる、
請求項14に記載の露光装置。 - 前記検出部は、投影された前記パターン光の像の照度を計測する照度センサを備える、
請求項1から請求項15のいずれか一項記載の露光装置。 - 描画データに対応したパターン光を生成する複数の素子を有する空間光変調器と、前記空間光変調器に照明光を照射する照明光学系と、前記空間光変調器により生成された前記パターン光の像を、第1移動体上に載置された物体上に投影する投影光学系と、を備える露光装置の前記空間光変調器を検査する検査方法であって、
投影された前記パターン光の像を検出することと、
前記パターン光の像の検出結果に基づいて、前記空間光変調器が前記描画データに応じた駆動をすることができない欠陥素子を有するか否かを判定することと、
を含む検査方法。 - 描画データに対応したパターン光を生成する複数の素子を有する空間光変調器と、前記空間光変調器に照明光を照射する照明光学系と、前記空間光変調器により生成された前記パターン光の像を、第1移動体上に載置された物体上に投影する投影光学系と、を備える露光装置の前記空間光変調器を検査する検査方法であって、
前記像を前記物体に露光することと、
前記像が露光された前記物体を計測装置を用いて計測することにより、前記空間光変調器が前記描画データに応じた駆動をすることができない欠陥素子を有するか否かを判定することと、
を含む検査方法。 - 描画データに対応したパターン光を生成する複数の素子を有する空間光変調器と、前記空間光変調器に照明光を照射する照明光学系と、前記空間光変調器により生成された前記パターン光の像を、第1移動体上に載置された物体上に投影する投影光学系を備える露光装置の前記空間光変調器を検査する検査方法であって、
前記空間光変調器が生成した前記パターン光の像をフォトクロミック素子に露光することと、
前記パターン光の像が露光された前記フォトクロミック素子を計測装置を用いて計測することにより、前記空間光変調器が前記描画データに応じた駆動をすることができない欠陥素子を有するか否かを判定することと、
を含む検査方法。 - 複数の素子を有する空間光変調器によって生成される描画データに応じたパターン光を物体に対して露光する露光装置であって、
前記空間光変調器に照明光を照射する照明光学系と、
前記物体を保持する第1移動体と、
前記空間光変調器により生成された前記パターン光を、前記物体に投影する投影光学系と、
前記物体上の前記パターン光の像の計測結果を得る計測部と、を備え、
前記計測部は、前記計測結果に基づいて、前記空間光変調器が前記描画データに応じた駆動をすることができない欠陥素子を有するか否かを計測する、露光装置。 - 複数の素子を有する空間光変調器によって生成される描画データに応じたパターン光を物体に対して露光する露光装置であって、
前記空間光変調器に照明光を照射する照明光学系と、
フォトクロミック素子を保持する第1移動体と、
前記空間光変調器により生成された前記パターン光を、前記フォトクロミック素子に投影する投影光学系と、
前記パターン光の像が投影された前記フォトクロミック素子の計測結果を得る計測部と、を備え、
前記計測部は、前記計測結果に基づいて、前記空間光変調器が前記描画データに応じた駆動をすることができない欠陥素子を有するか否かを判定する、露光装置。
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JPH0955349A (ja) * | 1995-08-14 | 1997-02-25 | Sony Corp | パターン形成方法および露光装置 |
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JP2006227345A (ja) * | 2005-02-18 | 2006-08-31 | Fuji Photo Film Co Ltd | 画素光ビーム欠陥検出方法および装置 |
JP2018205018A (ja) * | 2017-05-31 | 2018-12-27 | 株式会社ニコン | 検査装置及び検査方法、露光装置及び露光方法、並びに、デバイス製造方法 |
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JPH0955349A (ja) * | 1995-08-14 | 1997-02-25 | Sony Corp | パターン形成方法および露光装置 |
JP2003171525A (ja) * | 2001-12-05 | 2003-06-20 | Toray Ind Inc | 電磁波感応材料、塗料および積層物品 |
JP2006227345A (ja) * | 2005-02-18 | 2006-08-31 | Fuji Photo Film Co Ltd | 画素光ビーム欠陥検出方法および装置 |
JP2018205018A (ja) * | 2017-05-31 | 2018-12-27 | 株式会社ニコン | 検査装置及び検査方法、露光装置及び露光方法、並びに、デバイス製造方法 |
JP2020067387A (ja) * | 2018-10-25 | 2020-04-30 | 株式会社エスケーエレクトロニクス | 欠陥画素検出装置及び欠陥画素検出方法 |
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