U.S. patent number RE38,113 [Application Number 09/276,465] was granted by the patent office on 2003-05-06 for method of driving mask stage and method of mask alignment.
This patent grant is currently assigned to Nikon Corporation. Invention is credited to Seiro Murakami, Kenji Nishi.
United States Patent |
RE38,113 |
Nishi , et al. |
May 6, 2003 |
Method of driving mask stage and method of mask alignment
Abstract
In a scanning-type projection exposure system, curvature of a
movable mirror that is used to measure mask stage coordinate
positions is determined while the mask stage is moved in the
scanning direction, by measuring coordinate positions,
perpendicular to the scan direction, of the mask stage and of a
mask mark elongated in the scan direction. The results of the
measurements are used for correcting or compensating positional
deviation during scanning. Rotational deviation of a mask pattern
area is determined and is corrected or compensated. Also, a mask is
aligned with respect to a coordinate system of the mask stage as
pre-processing for exposure, using a mask alignment mark having two
crossing linear patterns and determining a coordinate position of
the crossing point by moving the mask relative to an observation
area.
Inventors: |
Nishi; Kenji (Yokohama,
JP), Murakami; Seiro (Chiba, JP) |
Assignee: |
Nikon Corporation (Tokyo,
JP)
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Family
ID: |
27465900 |
Appl.
No.: |
09/276,465 |
Filed: |
March 25, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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966353 |
Nov 7, 1997 |
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Reissue of: |
217841 |
Mar 25, 1994 |
05464715 |
Nov 7, 1995 |
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Foreign Application Priority Data
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Apr 2, 1993 [JP] |
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5-076045 |
Apr 13, 1993 [JP] |
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5-086066 |
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Current U.S.
Class: |
430/22; 355/53;
356/399; 356/400; 356/401; 430/5 |
Current CPC
Class: |
G03F
7/70358 (20130101); G03F 7/70775 (20130101); G03F
9/70 (20130101) |
Current International
Class: |
G03F
7/20 (20060101); G03F 9/00 (20060101); G03F
009/00 (); G01B 011/00 () |
Field of
Search: |
;430/5,22,30 ;250/492.2
;356/399,400,401 ;355/53 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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59-98446 |
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Jul 1984 |
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JP |
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62-150106 |
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Jul 1987 |
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JP |
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62-150721 |
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Jul 1987 |
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JP |
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63-128713 |
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Jun 1988 |
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JP |
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5-278813 |
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Oct 1993 |
|
JP |
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Other References
James Koch, "Laser Interferometers opto-electronic yardsticks",
Machine Design, pp. 93-97, Feb. 20.* .
U.S. patent application Ser. No. 06/943,808, Kakizaki et al., filed
Dec. 19, 1986..
|
Primary Examiner: Rosasco; S.
Attorney, Agent or Firm: Miles & Stockbridge P.C.
Parent Case Text
.Iadd.This is a continuation of Ser. No. 08/966,353 filed Nov. 7,
1997, now abandoned, which is a Reissue No. of 08/217,841 filed
Mar. 25, 1994, U.S. Pat. No. 4,464,715..Iaddend.
Claims
What is claimed is:
1. A method of driving a mask stage using an exposure device having
said mask stage which mounts a mask formed with a predetermined
pattern and is movable in a predetermined scan direction, a movable
mirror which is arranged on said mask stage and has a reflection
surface substantially parallel to the scan direction, measurement
means for measuring a coordinate position, in a direction
perpendicular to the scan direction, of said mask stage by
radiating a measurement beam onto said movable mirror, a substrate
stage which mounts a photosensitive substrate and is movable in a
direction substantially parallel to the scan direction, an
illumination system for illuminating a predetermined area on the
mask with illumination light, and a projection optical system for
projecting the pattern on the mask onto the photosensitive
substrate. said exposure device for sequentially exposing the
pattern on the mask onto the photosensitive substrate while
synchronously scanning said mask stage and said substrate stage in
the scan direction with respect to an optical axis of said
projection optical system, comprising the steps of: the first step
of placing the mask on said mask stage; the second step of
calculating a curved amount of said movable mirror by measuring the
coordinate position, in the direction perpendicular to the scan
direction, of said mask stage by said measurement means while
scanning said mask stage in the scan direction; and the third step
of moving said mask stage in the direction perpendicular to the
scan direction to correct the curved amount of said movable mirror
calculated in the second step when said mask stage is scanned in
the scan direction with respect to the optical axis; wherein the
mask has a measurement mark, and the second step includes the step
of calculating the curved amount of said movable mirror with
reference to the measurement mark.
2. A method of driving a mask stage using an exposure device having
said mask stage which mounts a mask formed with a predetermined
pattern and is movable in a predetermined scan direction, a movable
mirror which is arranged on said mask stage and has a reflection
surface substantially parallel to the scan direction, measurement
means for measuring a coordinate position, in a direction
perpendicular to the scan direction, of said mask stage by
radiating a measurement beam onto said movable mirror, a substrate
stage which mounts a photosensitive substrate and is movable in a
direction substantially parallel to the scan direction, an
illumination system for illuminating a predetermined area on the
mask with illumination light, and a projection optical system for
projecting the pattern on the mask onto the photosensitive
substrate, said exposure device for sequentially exposing the
pattern on the mask onto the photosensitive substrate while
synchronously scanning said mask stage and said substrate stage in
the scan direction with respect to an optical axis of said
projection optical system, comprising the steps of: the first step
of placing the mask on said mask stage; the second step of
calculating a curved amount of said movable mirror by measuring the
coordinate position, in the direction perpendicular to the scan
direction, of said mask stage by said measurement means while
scanning said mask stage in the scan direction; and the third step
of moving said mask stage in the direction perpendicular to the
scan direction to correct the curved amount of said movable mirror
calculated in the second step when said mask stage is scanned in
the scan direction with respect to the optical axis; wherein the
mask has a measurement mark, and the second step includes the step
of scanning said mask stage while the measurement mark is aligned
to a reference position, and calculating the curved amount of said
movable mirror on the basis of the coordinate position, in the
direction perpendicular to the scan direction, of said mask stage
measured by said measurement means.
3. A method of aligning a mask with respect to a coordinate system
on the side of a mask stage as pre-processing for exposing a
pattern on the mask onto a photosensitive substrate using an
exposure device having said mask stage which mounts the mask formed
with a predetermined pattern and is movable in a predetermined scan
direction, a substrate stage which mounts the photosensitive
substrate and is movable in a direction substantially parallel to
the scan direction, an illumination system for illuminating a
predetermined illumination area on the mask with illumination
light, a projection optical system for projecting the pattern on
the mask onto the photosensitive substrate, and observation means
for observing a mark on the mask, the exposure device for
sequentially exposing the pattern on the mask onto the
photosensitive substrate while synchronously scanning said mask
stage and said substrate stage in the scan direction with respect
to an optical axis of said projection optical system, comprising:
the first step of placing, as the mask, a mask formed with a first
alignment mark having two linear patterns which cross each other,
on said mask stage; the second step of moving the two linear
patterns .[.in a direction to cross each other on the first
alignment mark on the mask.]. relative to an observation area of
said observation means .Iadd.in a direction which is transverse to
each of the two linear patterns.Iaddend.; the third step of
calculating a coordinate position, in the coordinate system on the
side of said mask stage, of a crossing point of the two linear
patterns of the first alignment mark by processing image data
obtained by said observation means; and the fourth step of aligning
the mask to the coordinate system on the side of said mask stage on
the basis of the coordinate position of the crossing point of the
two linear patterns of the first alignment mark.
4. A method according to claim 3, wherein the mask has a second
alignment mark having two linear patterns which cross each other,
at a position different from the first alignment mark; said method
further comprises: the fifth step of moving the two linear patterns
.[.in a direction to cross each other on the second alignment mark
on the mask.]. relative to an observation area of said observation
means .Iadd.in a direction which is transverse to each of the two
linear patterns.Iaddend., and the sixth step of calculating a
coordinate position, in the coordinate system on the side of said
mask stage, of a crossing point of the two linear patterns of the
second alignment mark by processing image data obtained by said
observation means; and the fifth step comprises the step of
aligning the mask to the coordinate system on the side of said mask
stage on the basis of the coordinate position of the crossing point
of the two linear patterns of the first alignment mark and the
coordinate position of the crossing point of the two linear
patterns of the second alignment mark.
5. A method of aligning a mask with respect to a coordinate system
on the side of a mask stage as pre-processing for exposing a
pattern on the mask onto a photosensitive substrate using an
exposure device having said mask stage which mounts the mask formed
with a predetermined pattern and is movable in a predetermined scan
direction, a substrate stage which mounts the photosensitive
substrate and is movable in a direction substantially parallel to
the scan direction, an illumination system for illuminating a
predetermined illumination area on the mask with illumination
light, and a projection optical system for projecting the pattern
on the mask onto the photosensitive substrate, said exposure device
for sequentially exposing the pattern on the mask onto the
photosensitive substrate while synchronously scanning said mask
stage and said substrate stage in the scan direction with respect
to an optical axis of said projection optical system, comprising:
the first step of placing, as the mask, a mask formed with an
alignment mark, on said mask stage; and the second step of
calculating a rotational angle of the mask with respect to the
coordinate system on the side of said mask stage by calculating a
coordinate position of said alignment mark, and when the rotational
angle calculated in the second step exceeds a predetermined
allowable value, said method further comprising: the third step of
unloading the mask from said mask stage; the fourth step of
rotating said mask stage by a predetermined rotational angle in a
direction of the rotational angle calculated in the second step;
and the fifth stage of placing the mask on said mask stage again,
and rotating said mask stage in a direction opposite to the
rotational direction in the forth step.
6. A method of aligning a mask with respect to a coordinate system
on the side of a mask stage as pre-processing for exposing a
pattern on the mask onto a photosensitive substrate using an
exposure device having said mask stage which mounts the mask formed
with a predetermined pattern and is movable in a predetermined scan
direction, a substrate stage which mounts the photosensitive
substrate and is movable in a direction substantially parallel to
the scan direction, an illumination system for illuminating a
predetermined illumination area on the mask with illumination
light, and a projection optical system for projecting the pattern
on the mask onto the photosensitive substrate, said exposure device
for sequentially exposing the pattern on the mask onto the
photosensitive substrate while synchronously scanning said mask
stage and said substrate stage in the scan direction with respect
to an optical axis of said projection optical system, comprising:
the first step of placing, as the mask, a mask formed with an
alignment mark, on said mask stage; and the second step of
calculating a rotational angle of the mask with respect to the
coordinate system on the side of said mask stage by calculating a
coordinate position of said alignment mark, and when the rotational
angle calculated in the second step exceeds a predetermined
allowable value, said method further comprising: the third step of
rotating said mask stage in a direction opposite to the rotational
angle calculated in the second step; the fourth step of unloading
the mask from said mask stage; and the fifth step of rotating said
mask stage in a direction opposite to the rotational direction in
the third step, and placing the mask on said mask stage again.
7. A method of driving a mask when a mask stage carrying a mask
having a predetermined pattern and a mark for a measurement and a
substrate stage carrying a substrate are synchronously moved,
comprising the steps of: measuring a positional deviation of said
mask stage along a direction perpendicular to a movement direction,
by moving said mask stage along the movement direction while
measuring a position of said mask stage along the direction
substantially perpendicular to a movement direction and a position
of said mark relating to a direction substantially perpendicular to
the movement direction; and correcting the positional deviation
when said mask stage and said substrate stage are synchronously
moved, based on said measuring of positional deviation of said mask
stage, including said measuring of said position of said mask stage
and said measuring of said position of said mark.
8. A method according to claim 7, wherein said mark is elongated
along the movement direction.
9. An exposing apparatus synchronously moving a mask stage carrying
a mask having a predetermined pattern and a mark for a measurement
and a substrate stage carrying a substrate, to form the pattern
image onto said substrate, comprising: a position measuring system
for measuring a position of said mask stage along a direction
substantially perpendicular to a movement direction; a mark
detecting system for measuring a position of said mark; and a
control system for obtaining a positional deviation of said mask
stage along the direction substantially perpendicular to the
movement direction based on the result of the measurement of said
mark detecting system .Iadd.and the result of the measurement of
said position measuring system.Iaddend., and for correcting the
positional deviation, and for synchronously moving said mask stage
and said substrate stage. .Iadd.
10. Apparatus for driving a mask stage using an exposure device
having said mask stage which mounts a mask formed with a
predetermined pattern and is movable in a predetermined scan
direction, a movable mirror which is arranged on said mask stage
and has a reflection surface substantially parallel to the scan
direction, said reflection surface having an undesirable curvature,
a measurement system to measure a position, in a direction
perpendicular to the scan direction, of said mask stage by
radiating a measurement beam onto said reflection surface, and a
substrate stage which mounts a sensitive substrate, said exposure
device being operative for exposing the pattern on the mask onto
the sensitive substrate while scanning said mask stage in the scan
direction, said apparatus comprising a device connected to said
mask stage that moves said mask stage in the direction
perpendicular to the scan direction in accordance with said
undesirable curvature of said reflection surface so as to reduce an
undesirable effect on a pattern exposed onto the sensitive
substrate, when said mask stage is scanned in the scan direction
for an exposure..Iaddend..Iadd.
11. Apparatus for aligning a mask on a mask stage as pre-processing
for exposing a pattern on a mask onto a sensitive substrate using
an exposure device having said mask stage which mounts the mask
formed with said pattern and is movable in a predetermined scan
direction, and a substrate stage which mounts the sensitive
substrate, said exposure device being operative for exposing the
pattern on the mask onto the sensitive substrate while scanning
said mask stage in the scan direction, said apparatus comprising a
device connected to said mask stage which rotates said mask stage
by a predetermined rotational angle in a rotational direction
without the mask mounted on the mask stage and which rotates said
mask stage in a direction opposite to the rotational direction
after the mask is mounted on the mask stage..Iaddend..Iadd.
12. A scanning exposure method in which an exposure beam and an
object are moved relatively in a predetermined direction during a
scanning exposure, the method comprising: measuring information
relating to a curvature of a reflection surface which is
substantially parallel to the predetermined direction on a
supporting member for supporting the object, the reflection surface
being used for obtaining positional information of the supporting
member; and controlling an operation, in which the supporting
member is used, based on the measured
information..Iaddend..Iadd.
13. A scanning exposure method according to claim 12, wherein the
object includes a mask having a pattern..Iaddend..Iadd.
14. A scanning exposure method according to claim 13, wherein the
pattern of the mask is transferred onto a sensitive substrate and
wherein movement of the supporting member is controlled during the
scanning exposure, based on said measured information, such that
undesirable distortion does not occur in a pattern transferred on
the sensitive substrate..Iaddend..Iadd.
15. A scanning exposure method according to claim 12, wherein the
operation includes the scanning exposure..Iaddend..Iadd.
16. A scanning exposure method according to claim 12, wherein the
operation includes a control of a position of the supporting member
during the scanning exposure..Iaddend..Iadd.
17. A scanning exposure method according to claim 12, wherein the
measuring is performed while said supporting member is moved in
said predetermined direction..Iaddend..Iadd.
18. A scanning exposure method according to claim 12, wherein the
measuring is performed by using a mark of the object supported by
said supporting member..Iaddend..Iadd.
19. A scanning exposure method according to claim 12, wherein the
measuring includes obtaining positional information of said
reflection surface in a direction perpendicular to said
predetermined direction at plural positions in said predetermined
direction..Iaddend..Iadd.
20. A scanning exposure method according to claim 19, wherein said
positional information of said reflection surface includes a
deviation from a reference position of said reflection surface in
the direction perpendicular to said predetermined
direction..Iaddend..Iadd.
21. A scanning exposure method according to claim 12, wherein said
exposure beam includes light..Iaddend..Iadd.
22. A scanning exposure method according to claim 12, wherein said
reflection surface is used for obtaining positional information of
said supporting member in a direction orthogonal to said
predetermined direction by using an
interferometer..Iaddend..Iadd.
23. A scanning exposure method according to claim 12, further
comprising: detecting temperature information of said supporting
member to cope with a change in curvature of said reflection
surface based on the detecting..Iaddend..Iadd.
24. A method for manufacturing a device using a method according to
claim 12..Iaddend..Iadd.
25. A method of making a scanning exposure apparatus in which an
exposure beam and an object are moved relatively in a predetermined
direction during a scanning exposure, the method comprising:
providing a supporting member which is movable in the predetermined
direction while supporting the object; providing a reflection
surface which is substantially parallel to the predetermined
direction on the supporting member and which is used for obtaining
positional information of the supporting member; and providing a
measuring system which detects information relating to a curvature
of the reflection surface..Iaddend..Iadd.
26. A method according to claim 25, wherein the object includes a
mask having a pattern..Iaddend..Iadd.
27. A method according to claim 25, wherein said measuring system
includes an interferometer for obtaining positional information of
said supporting member in a direction orthogonal to said
predetermined direction by using said reflection
surface..Iaddend..Iadd.
28. A method according to claim 25, further comprising: providing a
control system that is connected with the supporting member and the
measuring system and that controls an operation, in which the
supporting member is used, based on the information detected by the
measuring system..Iaddend..Iadd.
29. A method according to claim 28, wherein the operation includes
a control of a position of the supporting member during the
scanning exposure..Iaddend..Iadd.
30. A method according to claim 25, wherein said supporting member
has a first driving mechanism for moving said object in said
predetermined direction and a second driving mechanism for fine
moving said object in said predetermined direction, in a direction
orthogonal to said predetermined direction, and in a rotational
direction..Iaddend..Iadd.
31. A method according to claim 30, further comprising: providing a
control system, connected with the measuring system and the second
driving mechanism, which controls the second driving mechanism
based on the information detected by the measuring
system..Iaddend..Iadd.
32. A scanning exposure apparatus in which an exposure beam and an
object are moved relatively in a predetermined direction during a
scanning exposure, the apparatus comprising: a supporting member
which is movable in the predetermined direction while supporting
the object; a reflection surface which is substantially parallel to
the predetermined direction on the supporting member and which is
used for obtaining positional information of the supporting member;
and a measuring system which detects information relating to a
curvature of the reflection surface..Iaddend..Iadd.
33. A scanning exposure apparatus according to claim 32, wherein
the object includes a mask having a pattern..Iaddend..Iadd.
34. A scanning exposure apparatus according to claim 32, wherein
said measuring system includes an interferometer for obtaining
positional information of said supporting member in a direction
orthogonal to said predetermined direction by using said reflection
surface..Iaddend..Iadd.
35. A scanning exposure apparatus according to claim 32, wherein
said measuring system includes a mark sensor which detects a mark
of the object supported by said supporting
member..Iaddend..Iadd.
36. A scanning exposure apparatus according to claim 32, further
comprising: a control system that is connected with the supporting
member and the measuring system and that controls an operation, in
which the supporting member is used, based on the information
detected by the measuring system..Iaddend..Iadd.
37. A scanning exposure apparatus according to claim 36, wherein
the operation includes the scanning exposure..Iaddend..Iadd.
38. A scanning exposure apparatus according to claim 36, wherein
the operation includes a control of a position of the supporting
member during the scanning exposure..Iaddend..Iadd.
39. A scanning exposure apparatus according to claim 32, wherein
said exposure beam includes light..Iaddend..Iadd.
40. A scanning exposure apparatus according to claim 32, wherein
said supporting member has a first driving mechanism for moving
said object in said predetermined direction and a second driving
mechanism for fine moving said object in said predetermined
direction, in a direction orthogonal to said predetermined
direction, and in a rotational direction..Iaddend..Iadd.
41. A scanning exposure apparatus according to claim 40, further
comprising: a control system, connected with the measuring system
and the second driving mechanism, which controls the second driving
mechanism based on the information detected by the measuring
system..Iaddend..Iadd.
42. A scanning exposure apparatus according to claim 33, further
comprising: a corner cube type reflection member on the supporting
member; and an interferometer device, optically connected with said
reflection member, which is used for obtaining positional
information of the supporting member in the predetermined
direction..Iaddend..Iadd.
43. A scanning exposure apparatus according to claim 33, further
comprising: a plurality of interferometers, functionally associated
with the supporting member, which are used for obtaining positional
information of the supporting member in the predetermined
direction..Iaddend..Iadd.
44. A scanning exposure apparatus according to claim 33, further
comprising: a temperature sensor, connected with the supporting
member, which is used for detecting a change in the curvature of
the reflection surface..Iaddend..Iadd.
45. A scanning exposure method comprising: moving an exposure beam
and an object relatively for a scanning exposure in a predetermined
direction, the object being supported by a supporting member and a
reflection surface being formed on the supporting member to obtain
positional information of the supporting member; and controlling a
movement of the supporting member, during the scanning exposure,
based on information relating to a curvature of the reflection
surface..Iaddend..Iadd.
46. A scanning exposure method according to claim 45, wherein the
object includes a mask having a pattern..Iaddend..Iadd.
47. A method according to claim 46, wherein the pattern of the mask
is transferred onto a sensitive substrate and wherein movement of
the supporting member is controlled during the scanning exposure,
based on said measured information, such that undesirable
distortion does not occur in a pattern transferred on the sensitive
substrates..Iaddend..Iadd.
48. A scanning exposure method according to claim 45 further
comprising: measuring the information relating to the curvature of
the reflection surface..Iaddend..Iadd.
49. A scanning exposure method according to claim 48, wherein the
measuring is performed while said supporting member is moved in
said predetermined direction..Iaddend..Iadd.
50. A scanning exposure method according to claim 48, wherein the
measuring is performed by using a mark of the object supported by
said supporting member..Iaddend..Iadd.
51. A scanning exposure method according to claim 48, wherein the
measuring includes obtaining positional information of said
reflection surface in a direction perpendicular to said
predetermined direction at plural positions in said predetermined
direction..Iaddend..Iadd.
52. A scanning exposure method according to claim 51, wherein said
positional information of said reflection surface includes a
deviation from a reference position of, said reflection surface in
the direction perpendicular to said predetermined
direction..Iaddend..Iadd.
53. A scanning exposure method according to claim 45, wherein the
reflection surface is substantially parallel to the predetermined
direction on the supporting member..Iaddend..Iadd.
54. A scanning exposure method according to claim 45, wherein said
exposure beam includes light..Iaddend..Iadd.
55. A scanning exposure method according to claim 45, wherein said
reflection surface is used for obtaining positional information of
said supporting member in a direction orthogonal to said
predetermined direction by using an
interferometer..Iaddend..Iadd.
56. A scanning exposure method according to claim 45, further
comprising: detecting temperature information of said supporting
member to respond to a change in curvature of said reflection
surface based on the detecting..Iaddend..Iadd.
57. A method of making a scanning exposure apparatus in which an
exposure beam and an object are moved relatively in a predetermined
direction during a scanning exposure, the method comprising:
providing a supporting member which is movable in the predetermined
direction while supporting the object; providing a reflection
surface which is formed on the supporting member and which is used
for obtaining positional information of the supporting member
during the scanning exposure; and providing a control system,
functionally associated with the supporting member, which controls
a movement of the supporting member based on information relating
to a curvature of the reflection surface..Iaddend..Iadd.
58. A method according to claim 57, wherein the object includes a
mask having a pattern..Iaddend..Iadd.
59. A method according to claim 57, further comprising: providing a
measuring system, functionally connected with the control system,
which detects the information relating to the curvature of the
reflection surface..Iaddend..Iadd.
60. A method according to claim 59, wherein said measuring system
includes an interferometer for obtaining positional information of
said supporting member in a direction orthogonal to said
predetermined direction by using said reflection
surface..Iaddend..Iadd.
61. A method according to claim 59, wherein the control system
controls the movement of the supporting member based on the
information detected by the measuring system..Iaddend..Iadd.
62. A method according to claim 57, wherein the reflection surface
is substantially parallel to the predetermined direction on the
supporting member..Iaddend..Iadd.
63. A method according to claim 57, wherein said supporting member
has a first driving mechanism for moving said object in said
predetermined direction and a second driving mechanism for fine
moving said object in said predetermined direction, in a direction
orthogonal to said predetermined direction, and in a rotational
direction..Iaddend..Iadd.
64. A method according to claim 63, wherein the control system
controls the second driving mechanism based on the information
relating to the curvature of the reflection
surface..Iaddend..Iadd.
65. A scanning exposure apparatus in which an exposure beam and an
object are moved relatively in a predetermined direction during a
scanning exposure, the apparatus comprising: a supporting member
which is movable in the predetermined direction while supporting
the object; a reflection surface which is formed on the supporting
member and which is used for obtaining positional information of
the supporting member during the scanning exposure; and a control
system, functionally associated with the supporting member which
controls a movement of the supporting member based on information
relating to a curvature of the reflection
surface..Iaddend..Iadd.
66. A scanning exposure apparatus according to claim 65, wherein
the object includes a mask having a pattern..Iaddend..Iadd.
67. A scanning exposure apparatus according to claim 65, further
comprising: a measuring system, functionally connected with the
control system, which detects the information relating to the
curvature of the reflection surface..Iaddend..Iadd.
68. A scanning exposure apparatus according to claim 67, wherein
said measuring system includes an interferometer for obtaining
positional information of said supporting member in a direction
orthogonal to said predetermined direction by using said reflection
surface..Iaddend..Iadd.
69. A scanning exposure apparatus according to claim 67, wherein
said measuring system includes a mark sensor which detects a mark
of the object supported by said supporting
member..Iaddend..Iadd.
70. A scanning exposure apparatus according to claim 67, wherein
the control system controls the movement of the supporting member
based on the information detected by the measuring
system..Iaddend..Iadd.
71. A scanning exposure apparatus according to claim 65, wherein
the reflection surface is substantially parallel to the
predetermined direction on the supporting
member..Iaddend..Iadd.
72. A scanning exposure apparatus according to claim 65, wherein
said exposure beam includes light..Iaddend..Iadd.
73. A scanning exposure apparatus according to claim 65, wherein
said supporting member has a first driving mechanism for moving
said object in said predetermined direction and a second driving
mechanism for fine moving said object in said predetermined
direction, in a direction orthogonal to said predetermined
direction, and in a rotational direction..Iaddend..Iadd.
74. A scanning exposure apparatus according to claim 73, wherein
the control system controls the second driving mechanism based on
the information relating to the curvature of the reflection
surface..Iaddend..Iadd.
75. A scanning exposure apparatus according to claim 65, further
comprising: a corner cube type reflection member on the supporting
member; and an interferometer, optically connected with said
reflection member, which is used for obtaining positional
information of the supporting member in the predetermined
direction..Iaddend..Iadd.
76. A scanning exposure apparatus according to claim 65, further
comprising: a plurality of interferometers, functionally associated
with the supporting member, which are used for obtaining positional
information of the supporting member in the predetermined
direction..Iaddend..Iadd.
77. A scanning exposure apparatus according to claim 65, further
comprising: a temperature sensor, connected with the supporting
member, which is used for detecting a change in the curvature of
the reflection surface..Iaddend..Iadd.
78. A scanning exposure method in which an object is moved relative
to an exposure beam during a scanning exposure, the method
comprising: moving a stage in a moving direction prior to the
scanning exposure, the object being supported on the stage, a
reflection surface being formed on the stage to obtain positional
information of the stage and the reflection surface being
substantially parallel to the moving direction; measuring
positional information of the stage in a direction crossing the
moving direction by applying a measuring beam of an interferometer
to the reflection surface, during the movement of the stage prior
to the scanning exposure; and controlling, during the scanning
exposure, movement of the stage based on the measured positional
information..Iaddend..Iadd.
79. A method according to claim 78, wherein the positional
information measured by said interferometer prior to the scanning
exposure changes in accordance with surface state of said
reflection surface..Iaddend..Iadd.
80. A method according to claim 78, wherein said stage is moved
along a guide upon moving in said moving
direction..Iaddend..Iadd.
81. A scanning exposure method according to claim 78, wherein the
object is a mask having a pattern..Iaddend..Iadd.
82. A scanning exposure method in which a mask and a substrate are
moved synchronously relative to an exposure beam during a scanning
exposure, the method comprising: moving a stage in a moving
direction prior to the scanning exposure, the mask being supported
on the stage, a reflection surface being formed on the stage to
obtain positional information of the stage and the reflection
surface being substantially parallel to the moving direction;
measuring positional information of the stage in a direction
crossing the moving direction by applying a measuring beam of an
interferometer to the reflection surface, during the movement of
the stage prior to the scanning exposure; and adjusting, during the
scanning exposure, positional relationship between the mask and the
substrate based on the measured positional
information..Iaddend..Iadd.
83. A method according to claim 82, wherein the positional
information measured by said interferometer prior to the scanning
exposure changes in accordance with surface state of said
reflection surface..Iaddend..Iadd.
84. A method according to claim 82, wherein the positional
relationship between the mask and the substrate is adjusted based
on the measured positional information such that undesirable
distortion does not occur in a shot area formed on said substrate
by the scanning exposure..Iaddend..Iadd.
85. A method according to claim 82, wherein the positional
relationship of the mask and the substrate is adjusted by
controlling a position of the stage based on the measured
positional information..Iaddend..Iadd.
86. A scanning exposure method according to claim 82, wherein the
interferometer has measuring axes perpendicular to the moving
direction..Iaddend..Iadd.
87. A microdevice manufacturing method including an exposure
process in which a mask and a substrate are moved in respective
scanning directions relative to an exposure beam during a scanning
exposure in order to form a device pattern on the substrate, the
method comprising: moving a stage in the scanning direction of the
mask prior to the scanning exposure, the mask being supported on
the stage, a reflection surface being formed on the stage, and the
reflection surface being substantially parallel to the scanning
direction of the mask; measuring positional information of the
stage in a direction crossing the scanning direction by applying a
measuring beam of an interferometer to the reflection surface,
during the movement of the stage prior to the scanning exposure;
and adjusting, during the scanning exposure, positional
relationship between the mask and the substrate based on the
measured positional information..Iaddend..Iadd.
88. A scanning exposure method in which an object is moved relative
to an exposure beam in a scanning direction during an exposure, the
method comprising: during the exposure, moving the object in the
scanning direction by using a first driving mechanism; during the
exposure, measuring position of the object by applying a measuring
beam of an interferometer to a reflection surface which is
substantially parallel to the scanning direction, the reflection
surface being moved in the scanning direction relative to the
measuring beam; and during the exposure, moving the object in a
non-scanning direction perpendicular to the scanning direction by
using a second driving mechanism in order to compensate for a
curvature of said reflection surface..Iaddend..Iadd.
89. A scanning exposure method according to claim 88, wherein the
second driving mechanism can finely move the object in the scanning
direction, the non-scanning direction, and in a rotational
direction..Iaddend..Iadd.
90. A scanning exposure method according to claim 88, wherein the
second driving mechanism includes a holding member which holds the
object, and wherein the reflection surface is formed on the holding
member..Iaddend..Iadd.
91. A scanning exposure method according to claim 90, further
comprising: prior to the exposure, moving the holding member in the
scanning direction, while applying the measuring beam to the
reflection surface, wherein the object is moved by using the second
driving mechanism during the exposure, based on output of the
interferometer obtained by moving the holding member in the
scanning direction prior to the exposure..Iaddend..Iadd.
92. A scanning exposure method according to claim 90, wherein the
interferometer has measuring axes perpendicular to the scanning
direction..Iaddend..Iadd.
93. A scanning exposure method according to claim 88, further
comprising: prior to the exposure, measuring information on the
curvature of the reflection surface, and wherein during the
exposure, the object is moved in the non-scanning direction based
on the measured information on the curvature..Iaddend..Iadd.
94. A scanning exposure method according to claim 88, wherein the
object includes a mask having a pattern..Iaddend..Iadd.
95. A scanning exposure method in which a mask and a substrate are
moved in respective scanning directions relative to an exposure
beam during an exposure, the method comprising: during the
exposure, moving the mask in the scanning direction by using a
first driving mechanism; during the exposure, measuring position of
the mask by applying a measuring beam of an interferometer to a
reflection surface extending substantially parallel to the scanning
direction, the reflection surface being moved in the scanning
direction relative to the measuring beam; and during the exposure,
moving the mask by using a second driving mechanism in order to
compensate for a curvature of said reflection
surface..Iaddend..Iadd.
96. A scanning exposure method according to claim 95, wherein the
mask is moved in a direction perpendicular to the scanning
direction by the second driving mechanism..Iaddend..Iadd.
97. A scanning exposure method according to claim 95, wherein the
mask is moved using the second driving mechanism such that
desirable distortion does not occur in a shot area to be formed on
the substrate by the scanning exposure..Iaddend..Iadd.
98. A scanning exposure method according to claim 95, wherein the
second driving mechanism can finely move the object in the scanning
direction, in a direction perpendicular to the scanning direction,
and in a rotational direction..Iaddend..Iadd.
99. A scanning exposure method according to claim 95, wherein the
second driving mechanism includes a holding member which holds the
mask, and wherein the reflection surface is formed on the holding
member..Iaddend..Iadd.
100. A scanning exposure method according to claim 99, further
comprising: prior to the exposure, moving the holding member in the
scanning direction, while applying the measuring beam to the
reflections surface, wherein the mask is moved by using the second
driving mechanism during the exposure, based on output of the
interferometer obtained by moving the holding member in the
scanning direction prior to the exposure..Iaddend..Iadd.
101. A scanning exposure method according to claim 99, wherein the
interferometer has measuring axes perpendicular to the scanning
direction..Iaddend..Iadd.
102. A scanning exposure method according to claim 95, further
comprising: prior to the exposure, measuring information on the
curvature of the reflection surface, and wherein during the
exposure, the mask is moved based on the measured information on
the curvature by using the second driving
mechanism..Iaddend..Iadd.
103. A microdevice manufacturing method including an exposure
process in which a mask and a substrate are moved in respective
scanning directions relative to an exposure beam during a scanning
exposure in order to form a device pattern on the substrate, the
method comprising: during the exposure, moving the mask in the
scanning direction by using a first driving mechanism; during the
exposure, measuring position of the mask by applying a measuring
beam of an interferometer to a reflection surface extending
substantially parallel to the scanning direction, the reflection
surface being moved in the scanning direction relative to the
measuring beam; and during the exposure, moving the mask by using a
second driving mechanism in order to compensate for a curvature of
said reflection surface..Iaddend..Iadd.
104. A method of making a scanning exposure device that is
operative for exposing a pattern on a mask onto a sensitive
substrate, comprising: providing a mask stage that is movable in a
predetermined scan direction and on which a mask formed with a
predetermined pattern is mountable; providing a movable mirror that
is arranged on said mask stage and that has a reflection surface
substantially parallel to the scan direction, said reflections
surface having an undesirable curvature; providing a measurement
system to measure a position, in a direction perpendicular to the
scan direction, of said mask stage by radiating a measurement beam
onto said reflection surface; providing a substrate state on which
a sensitive substrate is mountable; and providing a driver to move
said mask stage in a direction perpendicular to the scan direction
in accordance with said undesirable curvature of said reflection
surface so as to reduce an undesirable effect on a pattern exposed
onto the sensitive substrate, when said mask stage is scanned in
the scan direction for an exposure..Iaddend..Iadd.
105. A method of manufacturing a semiconductor device that employs
a sensitive substrate, using an exposure device having a mask stage
which mounts a mask that is formed with a predetermined pattern and
is movable in a predetermined scan direction, a movable mirror
which is arranged on said mask stage and has a reflection surface
substantially parallel to the scan direction, said reflection
surface having an undesirable curvature, a measurement system to
measure a position, in a direction perpendicular to the scan
direction, of said mask stage by radiating a measurement beam onto
said reflection surface, and a substrate stage which mounts said
sensitive substrate, said exposure device being operative for
exposing the pattern on the mask onto the sensitive substrate while
scanning said mask stage in the scan direction, said method
including: placing the mask on said mask stage; and moving said
mask stage in a direction perpendicular to the scan direction in
accordance with said undesirable curvature of said reflection
surface so as to reduce an undesirable effect on a pattern exposed
onto the sensitive substrate, when said mask stage is scanned in
the scan direction for an exposure..Iaddend.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of driving a mask stage
and a method of mask alignment. More particularly, the present
invention relates to a method of driving a stage, which is suitably
applied to a case where a reticle-side stage is driven in a scan
direction in a slit-scan exposure type projection exposure
apparatus, and a method of mask alignment in the projection
exposure apparatus.
2. Related Background Art
When a semiconductor element, a liquid crystal display element, a
thin film magnetic head, or the like is manufactured in a
photolithography process, a projection exposure apparatus for
transferring a pattern on a photomask or a reticle (to be generally
referred to as a "reticle" hereinafter) onto a substrate (a wafer,
glass plate, or the like) coated with a photosensitive material is
used.
As a conventional projection exposure apparatus, a step-and-repeat
type reduction projection exposure apparatus (stepper) for
sequentially exposing a pattern image on a reticle onto each of
shot areas by sequentially moving the shot areas of a wafer into an
exposure field of a projection optical system is popularly
used.
In recent years, since patterns on semiconductor devices or the
like tend to be miniaturized, it is required to increase the
resolution of a projection optical system. For this reason, in
order to increase the resolution, a technique for decreasing the
wavelength of exposure light, a technique for increasing the
numerical aperture of the projection optical system, and the like
have been examined. However, with either technique, it becomes
difficult to maintain high accuracy of imaging performance (a
distortion, curvature of field, and the like) on the entire
exposure field when an exposure field as large as that in the prior
art is to be assured. For this reason, an apparatus which is
currently reconsidered its use is a so-called slit-scan exposure
type projection exposure apparatus.
In the slit-scan exposure type projection exposure apparatus, a
pattern on a reticle is exposed onto a wafer, wherein the reticle
and wafer are being synchronously scanned relative to a rectangular
or arcuated illumination area (to be referred to as a "slit-like
illumination area" hereinafter).
Therefore, when a pattern with the same area as that in the stepper
system is to be exposed onto a wafer, the exposure field of the
projection optical system in the slit-scan exposure system can be
set to be smaller than that in the stepper system. As a result,
accuracy of imaging performance in the exposure field may be
improved.
The mainstream of the conventional reticle size is 6", and the
mainstream of the projection magnification of the projection
optical system is x1/5. However, as the area of the circuit pattern
of, e.g., a semiconductor element increases, the 6 " reticle cannot
serve its purpose at the x1/5 magnification. For this reason, a
projection exposure apparatus in which the projection magnification
of the projection optical system is changed to, e.g., x1/4 must be
designed. In order to cope with such an increase in area of a
pattern to be transferred, the slit-scan exposure system is
advantageous.
In a projection exposure apparatus of this type (stepper), a
reticle must be aligned in advance on a reticle stage. For this
purpose, a reticle alignment device is arranged on a reticle mark
on the reticle. Such a reticle alignment device is disclosed in
U.S. Pat. No. 4,710,029. In an alignment system disclosed in U.S.
Pat. No. 4,710,029, light reflected by an alignment mark on a
reticle is incident on a sensor via a vibration mirror and a slit.
When the output from the sensor is synchronously detected by a
driving signal of the vibration mirror, the position of the
alignment mark relative to a slit is detected. The position of the
alignment mark is detected based on a signal from the sensor in the
alignment system, and the reticle is moved by a servo system, so
that the alignment mark accurately coincides with the slit. As a
result, alignment of the reticle with respect to the apparatus main
body is executed.
SUMMARY OF THE INVENTION
In such a slit-scan exposure system, when the moving path of the
reticle stage for driving a reticle is curved with respect to a
desired path (for example, the moving path has a predetermined
curvature with respect to a desired linear path), each shot area on
a wafer undesirably has an intra-shot distortion according to the
curve (curvature) of the moving path of the reticle stage.
Furthermore, when the characteristics of an intra-shot distortion
vary from one exposure apparatus to another, such a variation
results in a matching error between different layers on the wafer.
When the reticle stage is controlled by a method of measuring the
position of the reticle stage by interfering light components
reflected by a stationary mirror and a movable mirror provided to
the reticle stage using an optical interferometer, such a curve of
the path of the reticle stage is caused by a curve of the movable
mirror.
The present invention has been made in consideration of the above
situation, and has as its object to provide a method of driving a
stage, which can prevent generation of an intra-shot distortion
even when a movable mirror provided to a stage at the side of
reticle (mask) has a curve in a slit-scan exposure type exposure
apparatus.
In order to achieve the above object, according to the first
invention, there is provided a method of driving a mask stage using
the mask stage which mounts a mask formed with a predetermined
pattern and is movable in a predetermined scan direction, a movable
mirror which is arranged on the mask stage and has a reflection
surface substantially parallel to the scan direction, measurement
means for measuring a coordinate position, in a direction
perpendicular to the scan direction, of the mask stage by radiating
a measurement beam into the movable mirror, a substrate stage which
mounts a photosensitive substrate and is movable in a direction
substantially parallel to the scan direction, an illumination
system for illuminating a predetermined area on the mask with
illumination light, a projection optical system for projecting the
pattern on the mask onto the photosensitive substrate, and an
exposure device for sequentially exposing the pattern on the mask
onto the photosensitive substrate while synchronously scanning the
mask stage and the substrate stage in the scan direction with
respect to an optical axis of the projection optical system,
comprising:
the first step of placing the mask on the mask stage;
the second step of calculating a curved amount of the movable
mirror by measuring the coordinate position, in the direction
perpendicular to the scan direction, of the mask stage by the
measurement means while scanning the mask stage in the scan
direction; and
the third step of moving the mask stage in the direction
perpendicular to the scan direction to correct the curved amount of
the movable mirror calculated in the second step when the mask
stage is scanned in the scan direction with respect to the optical
axis.
According to the second invention, there is provided a method of
driving a mask stage using a mask guide which is formed with a
guide portion extending in predetermined scan direction, the mask
stage which is mounted on the mask. Guide to be movable in the scan
direction, and mounts a mask formed with a predetermined pattern, a
movable mirror which is attached to the mask stage, and has a
reflection surface substantially parallel to the scan direction,
measurement means for measuring a coordinate position, in a
direction perpendicular to the scan direction, of the mask stage by
radiating a measurement beam into the movable mirror, a substrate
stage which is movable in the direction substantially parallel to
the scan direction and mounts a photosensitive substrate, an
illumination system for illuminating a predetermined area on the
mask with illumination light, a projection optical system for
projecting the pattern on the mask onto the photosensitive
substrate, and an exposure device for sequentially exposing the
pattern on the mask onto the photosensitive substrate while
synchronously scanning the mask stage and the substrate stage in
the scan direction with respect to an optical axis of the
projection optical system, comprising the steps of:
calculating a curved amount of the movable mirror by measuring the
coordinate position, in the direction perpendicular to the scan
direction, of the mask stage by the measurement means by scanning
the mask stage in the scan direction with reference to the mask
guide; and
moving the mask stage in the direction perpendicular to the scan
direction so as to correct the curved amount of the movable mirror
when a transfer mask is scanned via the mask stage in the scan
direction with respect to the predetermined shaped illumination
area.
According to the first invention, since the curved amount of the
movable mirror is measured with reference to the measurement mark
provided to the mask, and the measured curved amount is corrected
in exposure, even when the movable mirror provided to the mask
stage on the side of the mask has a curve, generation of an
intra-shot distortion at the substrate side can be prevented.
According to the second invention, since the curved amount of the
movable mirror is measured with reference to the mask guide, when
the straightness of the mask guide is good, the curve amount of the
movable mirror can be quickly and easily measured, and the measured
curved amount can be corrected in exposure.
In the slit-scan exposure type projection exposure apparatus as
well, when a reticle is exchanged with another one, the new reticle
must be aligned. However, in the slit-scan exposure system for
driving a reticle in a predetermined direction with high accuracy
during exposure, a reticle interferometer for monitoring the
position of the reticle with high accuracy must be mounted. For
this reason, it is difficult to assure larger driving strokes of
the reticle in the X and Y directions and the rotational direction
than those in a conventional stepper type projection exposure
apparatus upon alignment of a reticle. Therefore, it is difficult
to directly apply an alignment method used in the conventional
stepper to the slit-scan exposure type projection exposure
apparatus.
In general, the electron beam drawing error of a reticle mark with
respect to the outer shape of a reticle is about .+-.0.5 mm to
.+-.1 mm. In this case, when the reticle is aligned on the reticle
stage with reference to its outer shape, if a pattern drawing area
is inclined at a maximum inclination angle with respect to the
outer shape of the reticle, the lateral shift amount of a laser
beam from a reticle interferometer exceeds an allowable value of
the lateral shift amount in a receiver of the interferometer.
Therefore, it is difficult to completely correct the drawing error
of a reticle in the conventional alignment method without causing a
measurement error of the reticle interferometer.
Furthermore, an apparatus which mounts such a reticle
interferometer can align a reticle at an arbitrary position with
high accuracy by open-loop control. For this reason, an alignment
method which can detect the position of a reticle mark at high
speed by open-loop control must be developed in place of
conventional closed-loop control (servo control) based on
synchronous detection.
The present invention has been made in consideration of the above
situation, and has as its object to provide an alignment method
which can align a reticle (mark) at high speed with high accuracy
in a slit-scan exposure type projection exposure apparatus.
In order to achieve the above object, according to the third
invention, there is provided a method of aligning a mask with
respect to a coordinate system on the side of a mask stage as
pre-processing for exposing a pattern on the mask onto a
photosensitive substrate using the mask stage which mounts the mask
formed with a predetermined pattern and is movable in a
predetermined scan direction, a substrate stage which mounts the
photosensitive substrate and is movable in a direction
substantially parallel to the scan direction, an illumination
system for illuminating a predetermined illumination area on the
mask with illumination light, a projection optical system for
projecting the pattern on the mask onto the photosensitive
substrate, observation means for observing a mark on the mask, and
an exposure device for sequentially exposing the pattern on the
mask onto the photosensitive substrate while synchronously scanning
the mask stage and the substrate stage in the scan direction with
respect to an optical axis of the projection optical system,
comprising:
the first step of placing, as the mask, a mask formed with a first
alignment mark having two linear patterns which cross each other,
on the mask stage;
the second step of moving the two linear patterns in a direction to
cross each other on the first alignment mark on the mask relative
to an observation area of the observation means;
the third step of calculating a coordinate position, in the
coordinate system on the side of the mask stage, of a crossing
point of the two linear patterns of the first alignment mark by
processing image data obtained by the observation means; and
the fourth step of aligning the mask to the coordinate system on
the side of the mask stage on the basis of the coordinate position
of the crossing point of the two linear patterns of the first
alignment mark.
According to the fourth invention, there is provided a method of
aligning a mask with respect to a coordinate system on the side of
a mask stage as pre-processing for exposing a pattern on the mask
onto a photosensitive substrate using the mask stage which mounts
the mask formed with a predetermined pattern and is movable in a
predetermined scan direction, a substrate stage which mounts the
photosensitive substrate and is movable in a direction
substantially parallel to the scan direction, an illumination
system for illuminating a predetermined illumination area on the
mask with illumination light, a projection optical system for
projecting the pattern on the mask onto the photosensitive
substrate, and an exposure device for sequentially exposing the
pattern on the mask onto the photosensitive substrate while
synchronizing scanning the mask stage and the substrate stage in
the scan direction with respect to an optical axis of the
projection optical system, comprising:
the first step of placing, as the mask, a mask formed with an
alignment mark, on the mask stage; and
the second step of calculating a rotational angle of the mask with
respect to the coordinate system on the side of the mask stage by
calculating a coordinate position of the alignment mark, and when
the rotational angle calculated in the second step exceeds a
predetermined allowable value, the method further comprising:
the third step of unloading the mask from the mask stage;
the fourth of rotating the mask stage by a predetermined rotational
angle in a direction of the rotational angle calculated in the
second step; and
the fifth stage of placing the mask on the mask stage again, and
rotating the mask stage in a direction opposite to the rotational
direction in the fourth step.
According to the fifth invention, there is provided a method of
aligning a mask with respect to a coordinate system on the side of
a mask stage as pre-processing for exposing a pattern on the mask
onto a photosensitive substrate using the mask stage which mounts
the mask formed with a predetermined pattern and is movable in a
predetermined scan direction, a substrate stage which mounts the
photosensitive substrate and is movable in a direction
substantially parallel to the scan direction, an illumination
system for illuminating a predetermined illumination area on the
mask with illumination light, a projection optical system for
projecting the pattern on the mask onto the photosensitive
substrate, and an exposure device for sequentially exposing the
pattern on the mask onto the photosensitive substrate while
synchronously scanning the mask stage and the substrate stage in
the scan direction with respect to an optical axis of the
projection optical system, comprising:
the first step of placing, as the mask, a mask formed with an
alignment mark, on the mask stage; and
the second step of calculating a rotational angle of the mask with
respect to the coordinate system on the side of the mask stage by
calculating a coordinate position of the alignment mark, and when
the rotational angle calculated in the second step exceeds a
predetermined allowable value, the method further comprising:
the third step of rotating the mask stage in a direction opposite
to the rotational angle calculated in the second step;
the fourth step of unloading the mask from the mask stage; and
the fifth stage of rotating the mask stage in a direction opposite
to the rotational direction in the third step, and placing the mask
on the mask stage again.
According to the third invention, when the mask stage is driven
with respect to the observation area of the observation means so as
to obliquely scan the mask, the coordinate position of the crossing
point of the two linear patterns of the alignment mark on the mask
can be measured by the open-loop control. Therefore, mask alignment
can be realized at high speed with high accuracy.
According to the fourth and fifth inventions, when a mask is
re-placed on the mask stage upon occurrence of a rotation error of
the mask which poses a problem when a slit-scan exposure type mask
stage is used, mask alignment can be realized at high speed with
high accuracy. Also, strokes of the reticle stage upon alignment
need not be increased, and length measuring means need not have any
correction mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a projection exposure apparatus
according to an embodiment of the present invention;
FIG. 2A is a plan view showing the arrangement of a curve
measurement mark and an alignment mark on a reticle;
FIG. 2B is a plan view showing the arrangement of the alignment
mark and the like on an area conjugate with the effective field of
a projection optical system;
FIG. 2C is an enlarged view showing fine alignment marks 29A to
30D;
FIG. 3A is a plan view of a stage on the side of a wafer;
FIG. 3B is a plan view of a stage on the side of a reticle;
FIG. 4A is a projection view showing the mark arrangement on a
reticle;
FIG. 4B is a plan view showing the arrangement of reference marks
on a reference mark plate 6;
FIG. 4C is an enlarged view showing an example of a reference mark
35E (or 36E);
FIG. 5 is a partially cutaway schematic view showing the
arrangement of a reticle alignment microscope 19 and an
illumination system;
FIG. 6A is a view showing an image observed by an image pickup
element shown in FIG. 5; FIG. 6B is a waveform chart showing an
image signal in the X direction corresponding to the image shown in
FIG. 6A;
FIGS. 7A to 7D are waveform charts showing a curve which is
obtained by approximately measurement values upon measurement of
the curve of a movable mirror, and image signals corresponding to
respective portion of the movable mirror;
FIG. 8A is a plan view showing a reticle 12 of the embodiment;
FIG. 8B is an enlarged view showing a linear pattern 28c of a curve
measurement mark 28 in FIG. 8A;
FIG. 8C is an enlarged view showing another example of the curve
measurement mark;
FIG. 8D is an enlarged view showing still another example of the
curve measurement mark;
FIG. 9 is a schematic view showing another example of a reticle
alignment microscope;
FIG. 10A is a plan view showing of the curve of movable mirror on
the side of a reticle stage in a slit scan exposure type projection
exposure apparatus;
FIG. 10B is an enlarged view showing a distortion generated in a
shot area formed on a wafer due to the curve of the movable
mirror;
FIG. 10C is a plan view showing the arrangement of shot areas on
the wafer;
FIG. 11 is a perspective view showing a reticle loader system;
FIG. 12A is a plan view showing the arrangement of alignment marks
on a reticle;
FIG. 12B is a plan view showing the arrangement of alignment marks
and the like on an area conjugate with the effective field of a
projection optical system;
FIG. 12C is an enlarged view showing fine alignment marks 29A to
30A;
FIGS. 13A, 13B, 13C, 13D, 13E, and 13F are waveform charts showing
various image pickup signals obtained from an image pickup element
upon execution of rough alignment of a reticle;
FIG. 14A is an optical path chart showing the state of a laser beam
between an interferometer for the x-axis on the side of a reticle
stage and a movable mirror 21x;
FIG. 14B is an optical path chart showing a case whererin the
movable mirror 21X is rotated from the state shown in FIG. 14A;
and
FIGS. 15A, 15B, 15C, 15D, and 15E are views for explaining an
operation for re-placing a reticle 12 by rotating a reticle fine
driving state 11 when a pattern drawing area PA on the reticle 12
inclined with respect to a reticle coordinate system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of a projection exposure method according to the
present invention will be described below with reference to the
accompanying drawings. In this embodiment, the present invention is
applied to a case wherein a pattern on a reticle is exposed onto a
wafer using a slit-scan exposure type projection exposure
apparatus.
FIG. 1 shows a projection exposure apparatus of this embodiment.
Referring to FIG. 1, a pattern on a reticle 12 is illumination with
exposure light EL from an illumination optical system ILS. The
illumination optical system ILS forms a rectangular illumination
area (to be referred to as a "slit-like illumination area"
hereinafter) by the exposure light EL on the reticle 12. The
reticle pattern and the surface of a wafer 5 are optically
conjugate with each other with respect to a projection optical
system 8. A reticle pattern image of the slit-like illumination
area is projected and exposed onto the wafer 5 via the projection
optical system 8.
In this case, the wafer 5 is scanned at a constant velocity
V/.beta. (1/.beta. is the reduction factor of the projection
optical system 8) in the backward direction with respect to the
plane of the drawing of FIG. 1 (in the backward direction with
respect to the plane of the drawing in the Y-axis) in synchronism
with the reticle 12 which is scanned relative to the slit-like
illumination area of the exposure light EL at a constant velocity V
in the forward direction with respect to the plane of the drawing
of FIG. 1 (in the forward direction with respect to the plane of
the drawing in the Y-axis).
Driving systems of the reticle 12 and the wafer 5 will be described
below.
A reticle Y-driving stage 10, which is movable in the Y-axis
direction (the direction perpendicular to the plane of the drawing
of FIG. 1) is mounted on a reticle support table 9. A reticle fine
driving stage 11 is mounted on the reticle Y-driving stage 10. The
reticle 12 is held by, e.g., a vacuum chuck on the reticle fine
driving stage 11. The reticle fine driving stage 11 is finely
movable in the X direction parallel to the plane of the drawing of
FIG. 1 in a plane perpendicular to the optical axis of the
projection optical system 8, the Y direction perpendicular to the
plane of the drawing, and the rotational direction (8 direction) in
the X-Y plane. The reticle fine driving stage 11 performs position
control of the reticle 12 in the X, Y, and .theta. direction by a
very small amount with high accuracy.
A movable mirror 21 is arranged on the reticle fine driving stage
11.
An interferometer 14 arranged on the article support table 9
radiates a laser beam onto the movable mirror 21, and always
monitors the positions, in the X, Y, and 8 directions, of the
reticle fine driving stage 11 on the basis of light reflected by
the movable mirror.
Position information S1 obtained by the interferometer 14 is
supplied to a main control system 22A.
On the other hand, a wafer Y-axis driving stage 2, which is movable
in the Y-axis direction, is mounted on a wafer support table 1. A
wafer X-axis driving stage 3, which is movable in the X-axis
direction, is mounted on the wafer Y-axis driving stage 2. A
Z.theta.-axis driving stage 4 is arranged on the wafer X-axis
driving stage 3. The wafer 5 is held on the ZS-axis driving stage 4
by vacuum chucking.
A movable mirror 7 is also fixed on the Z.theta.-axis driving stage
4, and the positions, in the X, Y and .theta. directions, of the
Z.theta.-axis driving stage 4 are monitored by an interferometer 13
which is arranged outside the apparatus. Position information
obtained by the interferometer 13 is also supplied to the main
control system 22A. The main control system 22A controls the
alignment operations of the wafer Y-axis driving stage 2 to the
Z.theta.-axis driving stage 4 via a wafer driving device 22B and
the like, and also controls the operations of the entire
apparatus.
As will be described later, a reference or fiducial mark plate 6 is
fixed on the Z.theta.-axis driving stage 4 so as to attain a
correspondence between a wafer coordinate system and a reticle
coordinate system. The reference mark plate 6 is arranged near the
wafer 5. The wafer coordinate system is defined by coordinates
measured by the interferometer 13 on the wafer side, and the
reticle coordinate system is defined by coordinates measured by the
interferometer 14 on the reticle side. Various reference marks are
formed on the reference mark plate 6, as will be described later.
These reference marks include a luminous reference mark. The
luminous reference mark is a reference mark illuminated from the
back side with illumination light guided to the Z.theta.-axis
driving stage 4 side.
Reticle alignment microscopes 19 and 20 for simultaneously
observing the reference marks on the reference mark plate 6 and
marks on the reticle 12 are equipped above the reticle 12 of this
embodiment.
In this case, deflection mirrors 15 and 16 for guiding detection
light from the reticle 12 to the reticle alignment microscopes 19
and 20 are arranged. The deflection mirrors 15 and 16 are movable
in the X direction. When the exposure sequence is started, the
deflection mirrors 15 and 16 are respectively retreated from the
exposure light EL by mirror driving devices 17 and 18 in accordance
with an instruction from the main control system 22A.
Furthermore, an off-axis alignment device 34 for observating
alignment marks (wafer marks) on the wafer 5 is arranged on the
side surface portion, in the Y direction, of the projection optical
system 8.
The mechanism and operation for performing alignment of the reticle
12 and measurement of the curve of the movable mirror (to be
described later) will be described below.
FIG. 2A shows the arrangement of alignment marks (reticle marks)
and curve measurement marks on the reticle 12, and FIG. 2B shows a
slit-like illumination area 32 and the like in an area 33R
conjugate with the effective exposure field of the projection
optical system on the reticle. Assume that the scan direction is
defined as a y direction, and a direction perpendicular to the y
direction is defined as an x direction. Referring to FIG. 2A, a
light-shielding portion 31 is formed around a pattern area of a
central portion on the reticle 12. Marks formed outside the
light-shielding portion 31 are classified into curve measurement
marks 27 and 28, and fine alignment marks 29A, 29B, 29C, 29D, 30A,
30B, 30C, and 30D. The curve measurement mark 27 on the right side
is defined by a linear pattern 27c elongated along the y direction
as the scan direction, and cross patterns formed at the two end
portions of the linear pattern. The curve measurement mark 28 on
the left side is defined to have a linear pattern 28c symmetrical
with that of the curve measurement mark 27 on the right side.
As will be described later, the curve measurement marks 27 and 28
of this embodiment can also be used as alignment marks upon
execution of coarse alignment (rough alignment) of the reticle 12,
i.e., as rouch search alignment marks.
The fine alignment marks 29A and 29B are formed between a
light-shielding portion 31R on the right side and one cross pattern
of the curve measurement mark 27 so as to be close to each other in
the y direction, and the fine alignment marks 29C and 29D are
formed between the light-shielding portion 31R on the right side
and the other cross pattern of the curve measurement mark 27 so as
to be close to each other in the y direction. The fine alignment
marks 30A to 30D are formed on the left side to be symmetrical with
these fine alignments marks 29A to 29D. Each of these fine
alignment marks 29A to 29D and 30A to 30D is defined by arranging
two sets of three linear patterns at a predetermined interval in
the x direction, and arranging two sets of three linear patterns at
a predetermined interval in the y direction, as shown in FIG.
2C.
Upon execution of rough alignment of the reticle 12 in this
embodiment, the cross patterns of the curve measurement mark 28 on
the left side in FIG. 2A are detected by the reticle alignment
microscope (to be referred to as an "RA microscope" hereinafter) 20
in FIG. 1. Thereafter, the cross patterns of the curve measurement
mark 27 are moved to the observation area of the RA microscope 19,
and the position of the alignment mark 27 is similarly measured. In
this case, a pattern-free portion of the reference mark plate 6 in
FIG. 1 is moved into the exposure field of the projection optical
system 8, and is illuminated from its bottom portion. In this
manner, the curve measurement marks 27 and 28 are illuminated from
their rear surface side with illumination light emerging from the
reference mark plate 6.
In the above-mentioned sequence, the positions of the cross
patterns of the curve measurement marks 27 and 28 with respect to
the RA microscopes 19 and 20 in FIG. 1 can be obtained. More
specifically, the positional relationship between the reticle 12
and the reticle coordinate system can be roughly determined in the
above mentioned sequence. A rough correspondence between the RA
microscopes 19 and 20 and the wafer coordinate system can be
attained by measuring the reference marks on the reference mark
plate 6 in FIG. 1 by the RA microscopes 19 and 20. Thus, rough
alignment that can avoid an overlap between the fine alignment
marks 29A to 29D and 30A to 30D and the reference marks on the
reference mark plate 6 is completed. A mark search sequence in the
rough alignment will be described later.
The curve measurement sequence for the movable mirror and the fine
alignment sequence will be described below. Prior to the
description of these sequences, the detailed arrangement of the
wafer stage and the reticle stage will be explained.
FIG. 3A is a plan view of the wafer stage. Referring to FIG. 3A,
the wafer 5 and the reference mark plate 6 are arranged on the
Z.theta.-axis driving stage 4. An X-axis movable mirror 7X and a
Y-axis movable mirror 7Y are fixed on the Z.theta.-axis driving
stage 4. On the wafer 5, a slit-like illumination area 32W
corresponding to the slit-like illumination area 32 in FIG. 2B is
illuminated with exposure light, and observation areas 19W and 20W
are respectively conjugate with observation areas 19R and 20R in
FIG. 2B.
Laser beam LWX and LW.sub.of which are separated by an interval IL
are radiated onto the movable mirror 7X along optical paths which
are parallel to the X-axis and respectively pass the optical axis
of the projection optical system and the reference point of the
alignment device 34, and two laser beams LWY1 and LWY2 which are
separated by the interval IL are radiated onto the movable mirror
7Y along optical paths parallel to the Y axis. In exposure, the
coordinate value measured by an interferometer using the laser beam
LWX is used as the X-coordinate of the Z.theta.-axis driving stage
4, and an average value (Y.sub.1 +Y.sub.2) of coordinate values
Y.sub.1 and Y.sub.2 measured by interferometers which respectively
use the laser beams LWY1 and LWY2 is used as the Y coordinate. The
rotational amount of the Z.theta.-axis driving stage in the
rotational direction (.theta. direction) is measured based on e.g.,
the difference between the coordinate values Y.sub.1 and Y.sub.2.
Based on these coordinates, the position, on the X-Y plane, and the
rotational angle of the Z.theta.-axis driving stage 4 are
controlled.
In particular, in the Y direction as the scan direction
deterioration of accuracy caused by, e.g., an inclination upon
scanning is prevented using the average value of the measurement
results from the two interferometers. On the other hand, the
position in the X-axis direction when the off-axis alignment device
34 is used is controlled based on the measurement value from a
special-purpose interferometer using the letter beam LW.sub.of so
as to not cause a so-called Abbe's error.
FIG. 3B is a plan view of the reticle stage. Referring to FIG. 3B,
the reticle fine driving stage 11 is mounted on the reticle
Y-driving stage 10, and the reticle 12 is held thereon. An x-axis
movable mirror 21x and two y-axis movable mirrors 21y1 and 21y2 are
fixed to the reticle fine driving stage 11. Laser beams LRx are
radiated onto the movable mirror 21x in a direction parallel to the
x-axis, and laser beams LRy1 and LRy2 are radiated onto the movable
mirrors 21y1 and 21y2 in a direction parallel to the y-axis.
As in the wafer stage, the coordinate, in the y direction, of the
reticle fine driving stage 11 adopts an average value (y.sub.1
+y.sub.2)/2 of coordinate values y.sub.1 and y.sub.2 measured by
two interferometers using the laser beams LRy1 and LRy2.
Also, a coordinate value measured by an interferometer 14x using
the two laser beams LRx in the x direction is used. At this time,
an average value of the coordinate values measured using the two
laser beams may be used, or the coordinate value may be obtained
using either one laser beam LRx. In addition, the rotational
amount, in the rotational direction (.theta. direction), of the
reticle fine driving stage is measured based on e.g., the
difference between the coordinate values y.sub.1 and Y.sub.2.
In this case, as the movable mirrors 21y1 and 21y2 for the y
direction as the scan direction, corner cube type reflection
members are used. The laser beams LRy1 and LRy2 reflected by the
movable mirrors 21y1 and 21y2 are respectively reflected by
reflection mirrors 39 and 38, and are returned. More specifically,
the interferometers for the reticle are double-pass
interferometers, thereby preventing positional shifts of the laser
beams upon rotation of the reticle fine driving stage 11. Note that
the X-axis interferometer 14x may comprise a double-pass
interferometer.
As in the wafer stage, the slit-like illumination area 32 and the
observation areas 19R and 20R of the RA microscopes 19 and 20 are
arranged on the reticle 12. The reticle 12 and the ZS-axis driving
stage 4 in FIG. 3A can be observed from only the observation areas
19R and 20R.
The curve of the movable mirror 21x is measured by measuring the
relationship between the reticle 12 and the Z.theta.-axis driving
stage 4, as described above, and alignment accuracy in exposure and
rotational accuracy of the reticle 12 and wafer 5 can be
improved.
FIG. 4A shows a reticle image 12W obtained by projecting the
reticle 12 shown in FIG. 2A onto the reference mark plate 6 shown
in FIG. 3A. FIG. 4A illustrates mark images 29AW to 29DW conjugate
with the fine alignment marks 29A to 29D in FIG. 2A, and mark
images 30AW to 30DW conjugate with the fine alignment marks 30A to
30D. Furthermore, FIG. 4A illustrates mark images 27W and 28W
conjugate with the curve measurement marks 27 and 28.
FIG. 4B shows the arrangement of reference marks on the reference
mark plate 6. On the reference mark plate 6 in FIG. 4C, reference
marks 35E and 36E are formed to be separated by the same interval,
in the X direction, as that between the mark images 27W and 28W in
FIG. 4A. The reference mark 35E is defined by two linear patterns
of light-shielding portions arranged at a predetermined interval in
the X direction, as shown in FIG. 4C, and the same applies to the
reference mark 36E. These reference marks 35E and 36E are
illuminated with illumination light of the same wavelength as that
of the exposure light from the rear surface side.
Also, on the reference mark plate 6, reference marks 35A to 35D and
36A are formed to have substantially the same arrangement as that
of the mark images 29AW to 29DW and 30AW to 30DW in FIG. 4A. These
reference marks are illuminated with illumination light of the same
wavelength as that of the exposure light from the rear surface of
the reference mark plate 6. On the reference mark plate 6, a
reference mark 37A is formed at a position separated by an interval
IL in the Y direction as the scan direction from the middle point
between the reference marks 35A and 36A. The interval IL is equal
to a base line amount as an interval between the reference point in
an image field of the projection optical system 8 and the reference
point of the off-axis alignment device 34 in FIG. 1. Similarly,
reference marks 37B, 37C, and 37D are respectively formed at
positions separated by the interval IL in the Y direction from the
middle point between the reference marks 35B and 36B, the middle
point between the reference marks 35C and 36C, and the middle point
between the reference marks 35D and 36D.
Then, reticle 12 is finally aligned by measuring the positional
relationship between the fine alignment marks 29A to 29D and the
corresponding reference marks 35A to 35D using the RA microscope
19, and measuring the positional relationship between the fine
alignment marks 30A to 30D and the corresponding reference marks
36A to 36D using the RA microscope 20.
Upon measurement of the curve of the movable mirror 21x, the
positional shift amount between the reference mark 35E (or 36E) in
FIG. 4B and the linear pattern 27c (or the linear pattern 28c) of
the curve measurement mark 27 on the side of the reticle 12 in
FIGS. 2A is detected by the RA microscope 19 (or the RA microscope
20).
The arrangement of the RA microscope 19 and the like shown in FIG.
1 will be described in detail below for the purpose of explaining
the method of obtaining the positional shift amount.
FIG. 5 shows the RA microscope 19 and its illumination system.
Referring to FIG. 5, illumination light EL of the same wavelength
as that of the exposure light is guided from a portion outside the
Z.theta.-axis driving stage 4 to the interior of the Z.theta.-axis
during stage 4 via an optical fiber 44. In place of the optical
fiber 44, the exposure light may be relayed by a lens system. The
illumination light guided in this manner illuminates the reference
marks 35A to 35D on the reference mark plate 6 via a lens 45A, a
beam splitter 45B, and a lens 45C, and the illumination light
transmitted through the beam splitter 45B illuminates the reference
marks 36A to 36D on the reference mark plate 6 via lenses 45D and
45E, a mirror 45F, and a lens 45G. The illumination light can also
illuminate the reference marks 35E and 36E.
For example, light transmitted through the reference mark 35E forms
an image of the reference mark 35E on the linear pattern 27c on the
reticle 12 via the projection optical system 8. Light from the
optical image of the reference mark 35E and the linear pattern 27c
reaches a half mirror 42 via a deflection mirror 15, and lenses 40A
and 40B. The light is split into two light beams by the half mirror
42, and the two light beams are respectively incident on the image
pickup surfaces of x- and y-axis image pickup elements 43X and 43Y,
each comprising a two-dimensional CCD. Of these image pickup
elements, on an image pickup screen 43Xa of the image pickup
element 43X, the image of the reference pattern 27c and an image
35ER of the reference mark 35E are projected, as shown in FIG. 6A.
In this case, the direction of the horizontal scan line of the
image pickup screen 43Xa of the x-axis image pickup element 43X
corresponds to the x direction, and the direction of the horizontal
scan line of the image pickup screen of the y-axis image pickup
element 43Y corresponds to the y direction.
Therefore, the positional shift amount, in the x direction between
the image 35ER of the reference mark 35E and the linear pattern 27c
can be calculated from an additive mean of an image pickup signal
S4X from the image pickup element 43X. The image pickup signal S4X
is supplied to a signal processing device 41. The image pickup
signal S4X is detected to be a digital signal by analog/digital
conversion in the signal processing device 41. Image data on
respective scan lines are added and averaged on the. X-axis in the
signal processing device 41, and the image signal S4X on the X-axis
as the additive mean is as shown in FIG. 6B. These image data are
respectively processed as one-dimensional image processing signals.
On FIG. 6B, the abscissa of the image signal S4X corresponds to
time t. However, when the width of the image pickup screen of the
image pickup element 43X is measured in advance, the abscissa can
be regarded to plot a position x.
When the signal obtained as described above is subjected to
arithmetic processing in the signal processing device 41, a
position x.sub.3 in the x direction corresponding to the image of
the linear pattern 27c of the reticle 12 in FIG. 6A, a position
x.sub.1 corresponding to the left pattern of the image 35ER of the
reference mark 35E, and a position x.sub.2 corresponding to the
right pattern of the image 35ER can be obtained. A relative
positional shift amount .DELTA.x, in the x direction, between the
linear pattern 27c and the reference mark 35E is given by:
In this manner, the positional shift amount, in the x direction
between the linear pattern 27c of the curve measurement mark 27 in
FIG. 2A and the projected image of the reference mark 35E in FIG.
4B can be obtained. Similarly, the positional shift amount, in the
x direction, between the linear pattern 28c of the curve
measurement mark 28 in FIG. 2A and the projected image of the
reference mark 36E in FIG. 4B can be obtained using the RA
microscope 20.
Examples of a method of measuring the curved amount of the
reflection surface of the movable mirror 21x on the reticle stage
side in FIG. 3B using these potential shift amounts will be
described below.
The first method of measuring the curve of the movable mirror 21x
is a method executed with reference to the linear pattern 27c (or
the linear pattern 28c) of the curve measurement mark 27 in FIG.
2A. More specifically, in this case, in a state wherein the image
of the reference mark 35E and the linear pattern 27c are observed
by the RA microscope 19 to monitor the positional shift amount
.DELTA.x in the x direction therebetween, as shown in FIG. 5, and
in a state wherein the measurement value of the x-axis
interferometer 14x on the reticle side in FIG. 3B is maintained to
be a constant value, the reticle fine driving stage 11 is moved in
the y direction as the scan direction. Then, positional shift
amounts .DELTA.x.sub.i, in the x direction, between the image of
the reference mark 35E and the linear pattern 27c are calculated at
a large number of measurement positions y.sub.i in the y
direction.
FIG. 7A shows the results of plotting the positional shift amounts
.DELTA.x.sub.i at the measurement positions y.sub.i, a line 70 is a
straight line which extends straight in the y direction, and curve
71 is obtained by approximating a series of sampling points (points
with marks x in FIG. 7A). In the measurement data as the basis of
the curve 71, a positional shift amount .DELTA.x.sub.1 from the
straight line 70 is calculated to be the positional shift amount,
in the x direction, between a middle point 72 of the image 35ER of
the reference pattern 35E and the linear pattern 27c in the image
pickup signal S4X, as shown in FIG. 7B. Similarly, positional shift
amounts .DELTA.x.sub.n and .DELTA.x.sub.m are respectively
calculated from image pickup signals shown in FIGS. 7C and 7D.
FIGS. 7B to 7D show image pickup signals from the image pickup
element 43X. The sampling interval in the y direction is determined
by the curvature to be calculated, and the measurement accuracy of
the RA microscope 19 as an alignment sensor.
The respective relative positional shift amounts .DELTA.x.sub.i are
measured along the curve of the movable mirror 21x, as indicated by
the marks x in FIG. 7A.
Upon calculation of the curve 71, filtering is executed in a
software manner in accordance with a variation of the positional
shift amounts .DELTA.x.sub.i. A function corresponding to the
calculated curve 71 is approximately by a quadratic curve as a
function of the position y. For example, a coefficient A of the
term of y.sup.2 of the approximated function is calculated, and
when the reticle fine driving stage 11 is scanned in the y
direction in slit-scan exposure, the reticle fine driving state 11
is finely driven in the x direction in accordance with the position
in the y direction so as to cancel the curve of the movable mirror
21x. In this manner, an intra-shot distortion of a pattern image
exposed onto each shot area of the wafer 5 can be eliminated.
Referring to FIG. 7A, the curve 71 may be divided at proper
intervals in the y direction, and the respective curve sections may
be linearly approximated to obtain a coefficient B at each position
y. Correction may then be performed on the basis of the coefficient
B in the slit-scan exposure.
When image sampling is performed, in order to average reticle
drawing errors, additive mean values in the vertical direction may
be calculated for scan lines on the entire image pickup screen.
Alternatively, sampling may be performed while scanning the reticle
12, and the sampled values may be averaged.
In the above-mentioned embodiment, the reticle fine driving stage
11 is scanned in the y direction while maintaining the measurement
value, in the x direction, of the x-axis interferomenter 14x to be
a predetermined value. Conversely, the reticle fine driving stage
11 may be scanned in the y direction while the linear pattern 27c
is set at the middle point of the image 35ER of the reference mark
35E in FIG. 6A. In this case, the positional shift amount .DELTA.x
measured by the RA microscope 19 is always 0, and the measurement
value, in the x direction, of the x-axis interferometer 14x
directly represents the curved amount of the movable mirror
21x.
In the projection exposure apparatus, when heat is accumulated due
to exposure light radiated onto the pattern formation surface of
the reticle 12 in exposure, and a temperature change of the reticle
stage itself (the reticle fine driving stage 11) occurs, the curved
state of the movable mirror 21x may change. However, a temperature
sensor or the like may be arranged on the reticle stage to measure
the relationship between the temperature change amount and the
change in curved state in advance, and the correction coefficient
may be varied in accordance with the measurement result, thereby
canceling the change in curved state. Furthermore, after the curve
correction of the movable mirror 21x, when another reticle is set
and the same measurement is performed in the x- and y-axes, reticle
drawing errors at the respective positions can be measured. Since
the reticle drawing error between adjacent pattern portions is
small, reticle drawing errors from a position near the curve
measurement mark to the pattern portion are assumed to be almost
the same and are grouped, and the error group may be corrected in
slit-scan exposure, thus allowing reticle drawing error
correction.
FIG. 10A shows a case wherein the movable mirror 21x on the reticle
stage is curved. If the reflection surface of the movable mirror
21x is parallel to the straight line 70 which is perfectly parallel
to the y-axis, the pattern on the reticle 12 can be exposed on the
wafer without any distortion by scanning the reticle fine driving
stage 11 in the y direction in a state wherein the x coordinate
measured by the laser beam LRx is maintained to be a predetermined
value.
However, when the reflection surface of the movable mirror 21x is
curved to have a maximum shift amount .DELTA.x in the x direction,
as indicated by a solid curve in FIG. 10A, it is controlled to
maintain the position, on the reflection surface, of the laser beam
LRx from the interferometer to be the position of the straight line
70 indicated by a broken line upon scanning of the reticle 12.
Therefore, the reticle fine driving stage 11 is driven along a
curved path in a direction opposite to the curve of the movable
mirror 21x. As a result, as shown in FIG. 10B, each shot area 78 on
the wafer has an intra-shot distortion according to the curvature
of the moving path of the reticle fine driving stage 11. As shown
in FIG. 10C, the intra-shot distortion is common to all shot areas
79 on the wafer 5. In this case, if the characteristics of the
intra-shot distortion vary among exposure apparatuses, such a
variation results in a matching error between different layers on
the wafer.
As described above, when the reticle fine driving stage 11 is
scanned in the y direction in slit-scan exposure, the reticle fine
driving stage 11 is finely driven in the x direction in accordance
with the position in the y direction so as to cancel the curve of
the movable mirror 21x. Thus, the intra-shot distortion of the
pattern image exposed onto each shot area is eliminated, and a
matching error between different layers on the wafer can also be
eliminated.
In the above-mentioned embodiment, the curve measurement marks 27
and 28 shown in FIG. 8A are used as curve measurement marks, and
for example, the linear pattern 28c (see FIG. 8B) of the curve
measurement mark 28 is used as a reference upon measurement of the
curve of the movable mirror. However, as a reference used upon
measurement of the curve of the movable mirror, a multi-pattern 73
which is defined by aligning linear patterns, extending in the y
direction, in the x direction at a predetermined interval, as shown
in FIG. 8C, may be used. When the multi-pattern 73 is used, and the
measurement results of the linear patterns are averaged in the x
direction, the curved amount of the movable mirror can be measured
with higher accuracy. Also, as a reference used upon measurement of
the curve of the movable mirror, a multi-line-and-space pattern 74,
which is defined by aligning line-and-space patterns, formed at a
predetermined pitch the y direction, in the x direction at a
predetermined interval, as shown in FIG. 8D, may be used. The
multi-line-and-space pattern 74 can be easily formed on, e.g., a
reticle by an electron beam drawing device or the like.
In the above-mentioned embodiment, the positional shift amounts of
the linear patterns 27c and 28c are calculated with reference to
the reference marks 35E and 36E formed on the reference mark plate
6 on the wafer side. Alternatively, these reference marks may be
arranged in the RA microscope.
FIG. 9 shows an RA microscope which comprises internal reference
marks. Referring to FIG. 9, illumination light from the linear
pattern 27c on the reticle 12 is reflected by the half mirror 15,
and forms an image of the linear pattern 27c on an index plate 75
via lenses 40C and 49D. An index mark 76 defined by linear patterns
aligned at a predetermined interval in a direction conjugate with
the x direction on the reticle 12 is formed on the index plate 75,
and illumination light passing through the index plate 75 reaches
the half mirror 42 via a mirror 77 and lenses 40D and 40E. The
light is split into two light beams by the half mirror 42, and
these two beams are respectively incident on the image pickup
surfaces of the x- and y-axis image pickup elements 43X and 43Y.
Other arrangements are the same as those in the RA microscope 19
shown in FIG. 5.
In the RA microscope shown in FIG. 9, the positional shift amount
of the linear pattern 27c is detected with reference to the index
mark 76. Therefore, upon measurement of the curve of the movable
mirror 21x, the reference mark plate 6 on the wafer side need not
be used.
In the above-mentioned embodiment, the curve measurement marks 27
and 28 are used. However, in FIG. 3B, if the straightness of the
movement, in the y direction, of the reticle fine driving stage 11
is good, when the measurement values in the x direction are
monitored by the x-axis interferometer 14x while the reticle fine
driving stage 11 is simply scanned in the y direction, the
measurement values directly represent the curved amount of the
movable mirror 21x.
Next, a sequence from loading of the wafer 5 and the reticle 12 to
the end of alignment in the projection exposure apparatus of this
embodiment will be explained below. First, the reticle 12 is
pre-aligned with reference to its outer shape on a reticle loader
(to be described later).
FIG. 11 shows a reticle loader system for loading the reticle 12
onto the reticle fine driving stage 11 shown in FIG. 1. The reticle
loader shown in FIG. 11 is constituted by two reticle arms 23A and
23B, an arm rotation shaft 25 coupled to these reticle arms 23A and
23B, and a rotation mechanism 26 for rotating the arm rotation
shaft 25. Vacuum chucking grooves 24A and 24B are respectively
formed on the reticle placing surfaces of the reticle arms 23A and
23B, and the reticle arms 23A and 23B are supported to be
independently rotatable via the arm rotation shaft 25.
Upon loading of the reticle 12, the reticle 12 is transferred from
another reticle convey mechanism (not shown) onto the reticle arm
23A at a position A3. In this case, the other reticle arm 23B is
used for unloading the reticle used in the previous process. Then,
the reticle 12 is aligned to predetermined accuracy on the reticle
arm 23A with reference to its outer shape by a reticle outer shape
pre-alignment mechanism arranged near the position A3, and
thereafter, the reticle 12 is vacuum-chucked on the reticle arm
23A. The reticle outer shape pre-alignment mechanism is disclosed
in, e.g., FIG. 7 of U.S. Pat. No. 4,716,299, although not shown in
FIG. 11. The rotation mechanism 26 rotates the reticle arm 23A via
the arm rotation shaft 25 to convey the reticle 12 to a position B3
in the Y direction (in the direction of the reticle fine driving
stage 11 in FIG. 1).
At this time, since the vacuum chucking groove 24A is located at a
position in the direction perpendicular to the chucking position on
the reticle fine driving stage 11 and outside the pattern area of
the reticle 12, the reticle arm 23A can freely load/unload the
reticle 12 onto the reticle fine driving stage 11 in a state
wherein the reticle fine driving stage 11 is moved to a front
portion in the y direction as the scan direction. When the reticle
12 has reached a position above the reticle fine driving stage 11
(see FIG. 1), the arm rotation shaft 25 is moved downward in the -Z
direction. Then, the reticle 12 is placed on the vacuum chucking
surface on the reticle fine driving stage 11, and the reticle arm
23A retreats after the end of transfer of the reticle 12.
Thereafter, the reticle fine driving stage 11 conveys the reticle
12 in the direction of a position C3. In this case, the reticle
arms 23A and 23B are independently driven to respectively perform,
e.g., reticle loading and unloading operations at the same time,
thus increasing the reticle exchange speed.
Then, alignment of the reticle 12 is performed, and a mechanism and
operation therefor will be described below. As described above,
rough alignment of the reticle 12 can be performed using the curve
measurement marks 27 and 28. Thus, the rough alignment mechanism
and operation using the curve measurement marks (rough search
alignment marks) 27 and 28 will be described in detail below,
partially repeating the above-mentioned description.
After the reticle 12 is placed on the reticle fine driving stage
11, the curve measurement mark (rough search alignment mark) 28 on
the left side in FIG. 2A is detected by the RA microscope 20 in
FIG. 1. FIG. 2B shows the observation areas 19R and 20R, on the
reticle 12, of the RA microscopes 19 and 20 in this case. Upon
execution of rough search of the reticle 12, the curve measurement
marks (rough search alignment marks) 27 and 28 are respectively
located outside the observation areas 19R and 20R and outside the
area 33R conjugate with the effective exposure field. Although the
curve measurement marks (rough search alignment marks) 27 and 28
must have a large size for rough search, if the size of the
exposure field of the projection optical system is increased
accordingly, this results in an increase in cost. Thus, a procedure
upon execution of rough search in this embodiment will be described
below with reference to FIGS. 12A and 12B.
FIG. 12A is an enlarged view showing a portion near one cross
pattern of the curve measurement mark (rough search alignment mark)
28, and FIG. 12B shows FIG. 12A in the reduced scale. Referring to
FIGS. 12A and 12B, the widths, in the x and y directions, of a
square effective field 20R.sub.ef of the RA microscope 20 are
represented by W, and the design value of a sum of a drawing error
and a setting error of a pattern with respect to the outer shape of
the reticle 12 is represented by .DELTA.R. Therefore, as shown in
FIG. 12B, a square area having the width .DELTA.R always includes a
crossing point 28a of one cross pattern of the curve measurement
mark (rough search alignment mark) 28. An object to be detected is
the x- and y-coordinates of the crossing point 28a of the cross
pattern. In this embodiment, the reticle 12 is stepped via the
reticle fine driving stage 11 in a direction that crosses, at
45.degree., the two straight lines passing the crossing point 28a
of the curve measurement mark (alignment mark) 28, thereby scanning
the effective field 20R.sub.ef having the width W relative to a
position near the crossing point 28a obliquely with respect to the
x- and y-axes. Upon execution of the oblique scanning, the x- and
y-coordinates of the crossing point 28a are obtained as those of
the reticle fine driving stage 11 when the two straight lines
passing the crossing point 28a cross reference point in the
effective field 20R.sub.ef.
For this purpose, if the integral part of a positive real number a
is expressed by INT(a), the number of search frames as the minimum
number of times of scanning the square area having the width
.DELTA.R with the effective field 20R.sub.ef having the width W is
given by {INT(.DELTA.R/W)+1}. The number of search frames is
calculated in advance. Then, {INT(.DELTA.R/W)+1} effective fields
AS, BS, C5, . . . each having the width W are set in a square area
having the width .DELTA.R and including the effective field B5
(FIG. 12B) at substantially the central position, so that the edge
portions of the effective areas slightly overlap each other in the
45.degree. direction with respect to the x- and y-axes. The reticle
fine driving stage 11 (FIG. 1) is driven by the stepping method
under the open-loop control, and an image in each effective field
is sampled while setting each effective field in the effective
field 20R.sub.ef in FIG. 12A in turn.
As shown in FIG. 12B, the crossing point 28a of the curve
measurement mark (alignment mark) 28 to be searched is present
within at least a .DELTA.R.times..DELTA.R wide search range, and
the curve measurement mark (alignment mark) 28 is sufficiently
larger than the search range. Therefore, as can be understood from
the above description, when the effective field is stepped in the
oblique direction with respect to curve measurement mark (alignment
mark) 28, the coordinates of the crossing point 28a of the curve
measurement mark (alignment mark) 28 can be detected by the minimum
number of frames. Image processing at that time can be
one-dimensional image processing for an image signal obtained by
adding all scan lines in the pickup frame.
FIGS. 13A to 13F show various image signals obtained by adding all
scan lines. FIGS. 13A and 13D show image signals along the x and y
directions obtained in the effective field A5 in FIG. 12B, FIGS.
13B and 13E show image signals along the x and y directions
obtained in the effective field B5 in FIG. 12B, and FIGS. 13C and
13F show image signals along the x and y directions obtained in the
effective field C5 in FIG. 12B. The x-coordinate of the crossing
point 28a is calculated from the image signal shown in FIG. 13B,
and the y-coordinate of the crossing point 28a is calculated from
the image signal shown in FIG. 13F. Similarly, the RA microscope 20
detects the x- and y-coordinates of a crossing point 28b of the
other cross pattern of the curve measurement mark (alignment mark)
28 shown in FIG. 2A.
After the two-dimensional coordinate positions of the crossing
points 28a and 28b of the cross patterns at the two ends of the
curve measurement mark (alignment mark) 28 are detected, as
described above, the curve measurement mark (alignment mark 27) is,
in turn, moved to the observation area of the RA microscope 19, and
the two-dimensional coordinate positions of the crossing points 27a
and 27b of the cross patterns at the two ends of the curve
measurement mark (alignment mark) 27 are similarly detected. In
this case, a pattern-free portion of the reference mark plate 6 in
FIG. 1 is moved into the exposure field of the projection optical
system 8, and is illuminated from its bottom portion. In this
manner, the curve measurement marks 27 and 28 are illuminated from
their rear surface side with illumination light emerging from the
reference mark plate 6.
In the above-mentioned sequence, the positional relationship of the
curve measurement marks (alignment marks) 27 and 28 with respect to
the observation areas 19R and 20R of the RA microscopes 19 and 20
in FIG. 2B, and a rough positional relationship of the curve
measurement marks (alignment marks) 27 and 28 with respect to the
reticle coordinate system can be obtained. A rough correspondence
between the observation areas 19R and 20R of the RA microscopes and
the wafer coordinate system can be attained by measuring the
reference marks on the reference mark plate 6 (FIG. 1) using the RA
microscopes 19 and 20. Thus, rough alignment that can avoid an
overlap between the fine alignment marks 29A to 29D and 30A to 30D
and the reference marks (35A to 35D and 36A to 36D) on the
reference mark plate 6 in FIG. 4B is completed.
In this embodiment, in order to reduce the lens diameter of the
projection optical system 8, alignment marks on the reticle 12 are
classified into the curve measurement marks (alignment marks) and
fine alignment marks. However, when the projection optical system 8
can have a large lens diameter, these curve measurement marks
(alignment marks) and fine alignment marks can be common marks. In
this case as well, the technique for searching the curve
measurement marks (alignment marks) by stepping the stage in the
oblique direction (FIGS. 12A and 12B) can be adopted, and the RA
microscopes 19 and 20 can simultaneously search the curve
measurement marks (alignment marks).
The allowable value of a rotational angle when the reticle 12 of
this embodiment is placed on the reticle fine driving stage 11 will
be examined below. For this purpose, the arrangement of an
interferometer for measuring the coordinate, in the x direction, of
the reticle fine driving stage 11 on which the reticle 12 is
placed, as shown in FIG. 3B, will be partially described in detail
below with references to FIGS. 14A and 14B.
As shown in FIG. 14A, the x-axis interferometer (not shown in FIGS.
14A and 14B) radiates a laser beam LRx of p-polarized light onto a
polarization beam splitter 100. The laser beam LRx is transmitted
through a junction surface 100a of the polarized beam splitter
100a, passes through a quaterwave plate 101, and is then incident
on the x-axis movable mirror 21x in a state of circularly polarized
light. The laser beam LRx reflected by the movable mirror 21x is
reflected by the junction surface 100a of the polarization
beam.splitter 100 via a quaterwave plate 71 in a state of
s-polarized light, and propagates toward a corner cube 102. The
laser beam LRx reflected by the corner cube 102 is reflected by the
junction surface 100a of the polarization beam splitter 100, and is
incident on the movable mirror 21x in a state of circularly
polarized light via the quaterwave plate 101.
Thereafter, the laser beam LRx reflected by the movable mirror 21x
is incident on the junction surface 100a of the polarization beam
splitter 100 in a state of p-polarized light via the quaterwave
plate 71, and the laser beam LRx transmitted through the junction
surface 100a is returned to a receiver of the x-axis interferometer
(not shown). More specifically, when the movable mirror 21x is
displayed by .DELTA.x in the x direction, since the optical path
length of the laser beam LRx changes by 4.multidot..DELTA.x, the
x-axis interferometer on the reticle side also serves as a
double-pass interferometer. In this case, if the interval, in the y
direction, between the middle point in the y direction between the
laser beam LRx emerging from the interferometer and the laser beam
LRx returned to the interferometer, and the vertex of the corner
cube 102 is represented by La, and the interval, in the x
direction, from the movable mirror 21x to the vertex of the corner
cube 102 is represented by Lb, a distance L.sub.T of the path of
the laser beam LRx after the laser beam LRx is reflected by the
movable mirror 21x until the laser beam LRx passes through the
junction surface 100a of the polarization beam splitter is given by
the following equation:
In this case, as shown in FIG. 14B, when the reflection surface of
the movable mirror 21x is largely rotated at an an angle .theta.
about an axis perpendicular to the plane of the drawing of FIG. 14B
with respect to a plane perpendicular to the incident laser beam
LRx, the position, in the y direction, of the laser beam LRx
returned to the interferometer laterally shifted by an interval
.DELTA.L from a case wherein the angel .theta. is 0. The interval
.DELTA.L can be expressed as follows using the above-mentioned
distance L.sub.T :
Therefore, when the rotational angle .theta. of the movable mirror
21x exceeds an allowable value .theta..sub.1, the lateral shift
amount .DELTA.L of the laser beam LRx incident on the receiver of
the interferometer exceeds a predetermined allowable amount. Thus,
a reference beam and the laser beam LRx for length measurement can
no longer sufficiently overlap each other, resulting in a length
measurement error of the interferometer. In this case, the
allowable value .theta..sub.1 of the rotational angle which does
not cause an interferometer error is calculated in advance, and the
rotation error of the reticle 12 must be controlled not to exceed
the calculated allowable value .theta..sub.1 upon execution of
rough alignment of the reticle 12. The movable mirror 21x is
rotated when the pattern drawing area on the reticle 12 has been
rotated with respect to the reticle coordinate system defined by
the measurement value of the interferometer on the reticle side and
when the reticle fine driving stage 11 is rotated in a direction to
cancel the rotational angle of the pattern drawing area. Therefore,
in order to control the rotational angle .theta. of the movable
mirror 21x to be equal to or smaller than the allowable value
.theta..sub.1, the rotational angle of the pattern drawing area on
the reticle 12 must be controlled to be equal to or smaller than
the allowable value .theta..sub.1 upon execution of rough alignment
of the reticle 12.
In this embodiment, when the reticle 12 is placed on the reticle
fine driving stage 11, the rotational angle of the pattern drawing
area on the reticle 12 is controlled to be equal to or smaller than
the allowable value .theta..sub.1. The technique for attaining this
control will be described below with reference to FIGS. 15A, 15B,
15C, 15D, and 15E.
As shown in FIG. 15A, in an initial state of reticle loading, the
reticle 12 is aligned with reference to its outer shape, and is
vacuum-chucked on the reticle arm 23A. For the sake of descriptive
convenience, a pattern drawing area PA is largely inclined with
respect to the outer shape of the reticle 12. In this case, the
x-axis is assumed in a direction parallel to the laser beam LRx in
FIG. 3B, the y-axis is assumed in a direction parallel to the laser
beams LRy1 and LRy2, and the reticle coordinate system is formed by
these x- and y-axes. The inclination of the drawing area PA is
expressed by the crossing angle between a straight line passing the
two crossing points 27a and 27b at the two ends of one curve
measurement mark (rough search alignment mark) 27 (or a straight
line passing the two crossing points 28a and 28b at the two ends of
the other curve measurement mark (rough search alignment mark) 28),
and the y-axis of the reticle coordinate system. In this initial
state, an x.sub.RS -axis and a y.sub.Rs -axis are assumed on the
reticle fine driving stage 11 to be parallel to the x- and y-axes,
respectively.
Subsequently, as shown in FIG. 15B, after the reticle 12 is placed
on the reticle fine driving stage 11 by the reticle arm 23A, the
reticle arm 23A is escaped to the position B3. In this state, the
above-mentioned rough alignment is executed for the alignment marks
27 and 28, and a rotation angle (rotation error) .phi. of the
drawing area PA on the reticle 12 with respect to the y-axis of the
reticle coordinate system is measured. The rotational angle
.phi..sub.1 is obtained to be, e.g., an angle defined between a
straight line connecting the crossing points 27a and 27b at the two
ends of the alignment mark 27, and the y-axis. For the purpose of
descriptive convenience, assume that the drawing area PA is rotated
clockwise with respect to the y-axis.
When the rotational angle .phi..sub.1 exceeds the allowable value
.theta..sub.1, the reticle 12 is temporarily detached from the
reticle fine driving state 11 using the reticle arm 23A, as shown
in FIG. 15C. Then, the reticle fine driving stage 11 is rotated by
a mechanical limit angle .phi..sub.2 of the rotational angle in the
direction of the rotational angle .phi..sub.1. More specifically,
the y.sub.Rs -axis on the reticle fine driving stage 11 is rotated
clockwise by the limit angle .phi..sub.2 with respect to the
y-axis. Thereafter, as shown in FIG. 15D, the reticle 12 is
attached on the reticle fine driving stage 11 again using the
reticle arm 23A. The reticle fine driving stage 11 is then rotated
counterclockwise by the limit angle .phi..sub.2 with respect to the
y-axis, and is restored to the original position. Thus, as shown in
FIG. 15E, the angle of the drawing area PA of the reticle 12 with
respect to the y-axis of the reticle coordinate system becomes
smaller than the allowable value .theta..sub.1.
When the angle of the drawing area PA of the reticle 12 with
respect to the y-axis of the reticle coordinate system exceeds the
allowable value .theta..sub.1 even in the state shown in FIG. 15E,
the operations shown in FIGS. 15C to 15E can be repeated again. By
the operation for rotating the reticle fine driving stage 11 by one
revolution, the rotation error of even a reticle which has a
rotation error twice the allowable value .theta..sub.1 can be
suppressed to be equal to or smaller than the allowable value
.theta..sub.1. Furthermore, when the operation for rotating the
reticle fine driving stage 11, and restoring the stage 11 to an
original position is repeated n times (n is an integer equal to or
larger than 2), the rotation error of the drawing area PA on the
reticle 12 can be suppressed to be equal to or smaller than the
allowable value .theta..sub.1 regardless of the magnitude of the
rotation error in the initial state of the reticle 12. Thereafter,
the above-mentioned fine alignment is executed, thus completing the
alignment of the reticle 12.
When the rotational angle .phi..sub.1 of the drawing area PA on the
reticle 12 satisfies .theta..sub.1
<.phi..sub.1.ltoreq..phi..sub.2, the reticle fine driving stage
11 may be rotated by the rotational angle .phi..sub.1 of the
drawing area PA in place of being rotated by the mechanical limit
angle .phi..sub.2.
As described above, in this embodiment, since the positions of
reticle marks are detected using the image processing system while
stepping the reticle 12 in an obligue direction, measurement upon
execution of rough alignment of a reticle in the slit-scan exposure
type projection exposure apparatus can be realized. Furthermore, in
this embodiment, the image processing system for fine alignment is
also used for rough alignment, and a servo control system required
in a synchronous detection type alignment system like that
described in U.S. Pat. No. 4,710,029 is omitted. Thus, the
arrangement is simplified, and the manufacturing cost can be
reduced. When the rotational angle of the drawing area on the
reticle 12 exceeds an allowable value, the reticle 12 is detached
from the reticle fine driving stage 11, and after the reticle fine
driving stage 11 is rotated, the reticle 12 is attached again.
Since this sequence is adopted, a failure in reticle alignment can
be avoided.
In the above-mentioned embodiment, as shown in FIGS. 15B and 15C,
after the reticle 12 is detached from the reticle fine driving
stage 11, the reticle fine driving stage 11 is rotated by the
rotational angle .phi..sub.2. Alternatively, after the reticle fine
driving stage 11 is rotated in advance by -.phi..sub.2, the reticle
12 may be detached. In this case, as an operation corresponding to
FIGS. 15D and 15E, after the reticle fine driving stage 11 is
rotated by the rotational angle .phi..sub.2 to restore an original
state, the reticle 12 is attached again onto the reticle fine
driving stage 11. With this method as well, the rotational angle of
the drawing area on the reticle 12 can be controlled to be equal to
or smaller than the allowable value.
In the above-mentioned embodiment, as shown in FIGS. 15A to 15E,
when the rotational angle of the pattern drawing area PA on the
reticle 12 with respect to the reticle coordinate system exceeds
the allowable value, the reticle fine driving stage 11 is rotated.
Alternatively, the reticle 12 may be rotated in a direction
opposite to the rotational angel by the reticle arm 23A side from
which the reticle 12 is detached. For this purpose, a rotation
mechanism for rotating the article 12 on the reticle arm 23A may be
added.
Also, for a reticle having a reticle drawing error of the same
tendency with respect to the outer shape reference, a rotation
error caused by the reticle drawing error may be stored, and the
reticle fine driving stage 11 may be driven in the direction of an
axis defined by the rotation error. Thus, the reticle need not be
re-placed on the reticle fine driving stage 11. Furthermore, a
tracking error caused by shifting the movable mirror 21x in a
non-scan direction in slit-scan exposure due to the rotation error
can be decreased.
As described above, the present invention is not limited to the
above-mentioned embodiment, and may adopt various arrangements
within the spirit and scope of the invention.
* * * * *