US20060056083A1 - Retainer, exposure apparatus, and device fabrication method - Google Patents
Retainer, exposure apparatus, and device fabrication method Download PDFInfo
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- US20060056083A1 US20060056083A1 US11/265,434 US26543405A US2006056083A1 US 20060056083 A1 US20060056083 A1 US 20060056083A1 US 26543405 A US26543405 A US 26543405A US 2006056083 A1 US2006056083 A1 US 2006056083A1
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- optical element
- lens
- optical
- retainer
- optical system
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Images
Classifications
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B7/00—Mountings, adjusting means, or light-tight connections, for optical elements
- G02B7/18—Mountings, adjusting means, or light-tight connections, for optical elements for prisms; for mirrors
- G02B7/182—Mountings, adjusting means, or light-tight connections, for optical elements for prisms; for mirrors for mirrors
- G02B7/183—Mountings, adjusting means, or light-tight connections, for optical elements for prisms; for mirrors for mirrors specially adapted for very large mirrors, e.g. for astronomy, or solar concentrators
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- G02B7/00—Mountings, adjusting means, or light-tight connections, for optical elements
- G02B7/02—Mountings, adjusting means, or light-tight connections, for optical elements for lenses
- G02B7/027—Mountings, adjusting means, or light-tight connections, for optical elements for lenses the lens being in the form of a sphere or ball
Definitions
- the present invention relates generally to precision machines for mounting an optical element, and more particularly to a projection optical system in an exposure apparatus, etc.
- the present invention is suitable, for example, for a retainer that holds an optical element for a more precise imaging relationship in an exposure apparatus in projecting and exposing an image on an original sheet, such as a mask or reticle (these terms are used interchangeably in this application) onto an object, such as a single crystal substrate for a semiconductor wafer, a glass plate for a liquid crystal display (LCD).
- the exposure apparatus is used to fabricate a semiconductor device, an image pick-up device (such as a CCD), and a thin film magnetic head.
- the fabrication of a device using the lithography technique has employed a projection exposure apparatus that uses a projection optical system to project a circuit pattern formed on a mask onto a wafer and the like, thereby transferring the circuit pattern.
- the projection optical system enables diffracted beams from the circuit pattern to interfere on the wafer and the like, so as to form an image.
- the devices to be mounted on electronic apparatuses should be highly integrated to meet recent demands for miniaturization and low profile of electronic apparatuses, and finer circuit patterns to be transferred or higher resolution have been demanded increasingly.
- a short wavelength of a light source and an increased numerical aperture (“NA”) in a projection optical system are effective to the high resolution as well as a reduced aberration in the projection optical system.
- An optical element such as a lens and a mirror, when deforming in an projection optical system causes aberration because an optical path refracts before and after the deformation and light that is supposed to form an image at one point does not converge on one point.
- the aberration causes a positional offset and short-circuits a circuit pattern on a wafer.
- a wider pattern size to prevent short-circuiting is contradictory to a fine process.
- a projection optical system with small aberration should hold its optical element(s) without changing a shape and a position relative to the optical axis of the optical element in the projection optical system so as to maximize the original optical performance of the optical element.
- the projection lens tends to have a larger caliber and a larger lens capacity due to the recent high NA in the projection optical system, and easily deforms by its own weight.
- diffraction optical elements which have been eagerly studied recently, also tend to deform due to its thinness.
- Japanese Patent Application, Publication No. 2001-284226 proposes, as shown in FIG. 11 , a retainer 1000 that fixes a lens 1300 using three or more (e.g., thirty in the embodiment) lens support points 1200 formed on a cell 1100 , and springs 1400 for pressing the lens 1300 from a side opposite to the lens support points 1200 .
- a compression force is designed or calculated to the extent that a lens of a low breaking strength, such as a lens made of calcium fluoride (CaF 2 ), does not get damaged.
- FIG. 11 is an exploded perspective view of the exemplary conventional retainer 1000 .
- Japanese Patent Application, Publication No. 2001-74991 proposes, as shown in FIG. 12 , a retainer 2000 that fixes a lens installed onto seats on three flex mount parts 2200 that are radially arranged at regular intervals on an inner circumference on a cell 2100 , and a spring member with small rigidity in a non-optical axis direction for applying a compression force to the lens from the top of the lens according to the lens shape.
- Soft mount parts 2300 dispersedly support the lens among the flex mount parts 2200 so as to minimize the gravity deflection and so as not to excessively restrain the positioning of the lens.
- FIG. 12 is a schematic top transparent view showing the exemplary conventional retainer 2000 .
- Japanese Patent Application, Publication No. 2001-284226 does not consider the flatness of the lens support points 1200 and lens deformation. For example, when the heights of the lens support points 1200 deviate, only three points among them support points 1200 even when there are thirty or more lens. Therefore, the portion except the above three support points does not contact the lens but receives forces from the springs 1400 , causing the lens to deform. Thus, this reference has a difficulty in realizing a projection optical system with little aberration due to such a lens's deformation.
- Japanese Patent Application, Publication No. 2001-74991 has a careful structure to a lens deformation or distortion, but requires forces opposite to those applied by the flex mount parts at three flex mount parts 2200 so as to apply a compression force to prevent the lateral offset of the lens. This causes the lens to incur a large load from the spring members of the flex mount parts 2200 . This causes the large birefringence and possibly breaks the lens, and has a difficulty in realization.
- a retainer includes a plurality of support members for supporting an optical element, and a plurality of elastic members arranged between the plurality of support members, each elastic member applying an elastic force to the optical element in a direction perpendicular to the gravity direction.
- An exposure apparatus of another aspect of the present invention includes the above retainer, and an optical system for exposing a pattern formed on a mask or reticle onto an object through the optical element held by the retainer.
- a device fabrication method of another aspect of the present invention includes the steps of exposing a pattern on a mask, onto an object by using the above exposure apparatus, and developing the exposed object.
- FIG. 1 is a schematic sectional and perspective view of a retainer of one embodiment according to the present invention applicable to a projection optical system in an exposure apparatus.
- FIG. 2 is an enlarged typical view of principal part of an optical member at its outer circumference side surface as indicated by a broken line A in FIG. 1 .
- FIG. 3 is an enlarged exploded perspective view of a support member shown in FIG. 1 .
- FIG. 4 is a schematic block view of the exemplary exposure apparatus according to the present invention.
- FIG. 5 is an enlarged exploded perspective view of the support member shown in FIG. 1 .
- FIG. 6 is an enlarged exploded perspective view of an elastic member shown in FIG. 1 .
- FIG. 7 is a schematic sectional view showing a contact state between a groove in an optical member and a forcing surface of the elastic member.
- FIG. 8 is a schematic structure of an exemplary inventive exposure apparatus.
- FIG. 9 is a flowchart for explaining how to fabricate devices (such as semiconductor chips such as ICs and LCDs, CCDs, and the like).
- FIG. 10 is a detail flowchart of a wafer process as Step 4 shown in FIG. 9 .
- FIG. 11 is an exploded perspective view of a conventional exemplary retainer.
- FIG. 12 is a schematic top transparent view of another conventional exemplary retainer.
- FIG. 1 is a schematic sectional and perspective view of the inventive retainer applicable to the projection optical system in the exposure apparatus 200 .
- the gravity direction and the antigravity direction are parallel to the optical axis of the optical element 110 , as shown in an arrow direction in FIG.
- the instant embodiment applies the present invention to a case where the optical axis of the optical element is parallel to the gravity and anti-gravity directions.
- the retainer 100 includes a cell member 120 , the support parts 130 , and an elastic member 140 , and holds the optical element 110 .
- the optical element 110 has a sectionally V-shaped groove 112 on its outer circumference side surface, and is mounted on the support parts 130 , which will be described later.
- FIG. 2 is an enlarged typical view of principal part of an optical member 110 at its outer circumference side surface (or the groove 112 ) as indicated by a broken line A in FIG. 1 .
- the optical element 110 images light using reflections, refractions, diffractions, etc.
- the optical element 110 includes, for example, a lens, a parallel plate glass, a prism, a mirror, and a Fresnel zone plate, a kinoform, a binary optics, a hologram, and other diffraction optical elements.
- the optical element 110 may be placed on and supported by the support members 130 .
- the optical element 110 is compressed against the side opposite to the support members 130 when viewed from the optical element.
- a compression member is provided to fix a position in an optical-axis (or vertical) direction of the optical element 110 .
- the groove 112 has, but is not limited to, a V-shaped section, and may have a circular section and another shape.
- the cell member 120 mounts three support parts 130 for supporting the optical element 110 at three points, and the elastic member 140 , which will be described later.
- the cell member 120 is a ring member formed around the optical axis, and made of a material having a coefficient of linear expansion substantially equal to that of the optical element 110 .
- the optical element 110 is a quartz lens
- the cell uses a super-inver material. This structure may prevent the external force from deforming or stressing the optical element 110 via the support members 130 and the elastic members 140 due to a relative displacement resulting from different linear expansions between the optical element 110 and the cell member 120 .
- FIG. 3 shows an enlarged exploded perspective view of the support part 130 shown in FIG. 1 .
- the support part 130 has, as shown in FIG. 3 , a contact part 132 for contacting the optical element 110 's groove 112 to support the optical element 110 at three points via the groove 112 .
- the support part 130 is arranged at three points on the cell member 120 at approximately regular intervals around the optical axis.
- the support parts 130 are distributed on the optical element 110 in its circumferential direction at approximately regular intervals, and stably support the optical element 110 .
- the contact part 132 at the tip of the support part 130 forms, for example, a spherical absorption member 132 a to support the optical element 110 and contacts the sectionally V-shaped groove 112 at its two points as shown in FIG. 4 , without damaging the optical element 110 . Therefore, the optical element 110 is positioned in the optical-axis (or vertical) direction without being excessively restrained.
- FIG. 4 is a schematic sectional view showing a contact state between the groove 112 in the optical element 110 and the absorption member 132 a of the support member 130 .
- three cone-shaped hole 114 each corresponding to the spherical absorption member 132 a may be provided at regular intervals on the outer circumferential side surface of the optical element 110 to allow the absorption members 132 a of the support member 130 to contact the holes 114 .
- at least one of three support members 130 preferably has the contact part 132 (and the absorption member 132 a ) which includes a spring mechanism 132 b that is deformable in a radial direction of the optical element 110 , in order to avoid deformations of the optical element 110 due to excessive restraints.
- FIG. 5 is an enlarged exploded perspective view of the support part 130 shown in FIG. 1 .
- the support part 130 is connected to the cell member 120 via a pin P 1 .
- the elastic members 140 are provided among three support members 130 . At least one (preferably plural) elastic members 140 are provided between two adjacent support members along the peripheral part of the optical element.
- the elastic members 140 apply an elastic force in the antigravity direction and a direction perpendicular to the antigravity direction.
- the elastic member 140 is coupled to the cell member 120 via the pin P 2 and the spacer S 1 as shown in FIG. 6 . It is preferable that the elastic member elastically deforms in the antigravity or gravity direction (or along an optical-axis direction of the optical element 110 ), and does not elastically deform in the horizontal direction (or a radial direction of the optical element 110 ).
- the elastic member deforms only in a predetermined direction, which is substantially the antigravity or gravity direction (or an optical-axis direction of the optical element 110 ), or an angle between the predetermined direction and the antigravity or gravity direction is within 5°.
- the elastic member 140 is made, for example, of a flat spring.
- FIG. 6 is an enlarged exploded perspective view of the elastic member 140 shown in FIG. 1 .
- the elastic member 140 has a forcing surface 142 that has a curvature to contact the sectionally V-shaped groove 112 in the optical element 110 and applies an elastic force to the optical element 110 in the antigravity direction and the direction perpendicular to the antigravity direction.
- the forcing surface 142 is formed by bending a tip of the elastic member 140 (i.e., a part that contacts the groove 112 in the optical element 110 ) in a pipe shape.
- the elastic member 140 is positioned in the optical-axis direction and fixed against the cell member 120 so that two outer circumferential points on the pipe-shaped forcing surface 142 contact the sectionally V-shaped groove 112 in the optical element 110 .
- a position of the elastic member 140 is adjustable by changing the height of the cell member 120 in the optical-axis direction or the height of a spacer in the optical-axis direction, which is provided between the cell member 120 and the elastic member 140 .
- the elastic member displaces in the gravity direction, and provides the elastic force in the antigravity direction.
- the elastic member 140 applies an elastic force to the elastic element 110 in the antigravity direction and the direction perpendicular to the antigravity direction via the contact points A and B, at which the elastic member 140 contacts the groove 112 in the optical element 110 .
- the elastic force in the antigravity direction which occurs as the elastic member 140 displaces in the gravity direction, is applied to the optical element 110 via the forcing surface 142 after divided into an elastic force A 1 in the antigravity direction and an elastic force A 2 in the direction perpendicular to the antigravity direction.
- FIG. 7 is a schematic sectional view showing a contact state between the groove 112 in the optical member 110 and the forcing surface 142 of the elastic member 140 .
- the elastic force A 1 applied to the optical element 110 by the elastic member 140 pushes up the optical element 110 in the antigravity direction, and the elastic forces A 2 and B 1 applied to the optical element 110 by the elastic member 140 position the optical element 110 in a direction perpendicular to the optical-axis direction or a lateral direction.
- a sum of the elastic forces A 1 applied by the elastic members 140 is equal to the weight of the optical element.
- the gravity deformation of the optical element 110 can be reduced, if a load F of the elastic force A 1 applied by each elastic member 140 is set so that Equation 1 below is met, where n is the number of elastic members 140 , and M is the weight of the optical element 110 .
- F M/n (1)
- the retainer 100 positions the optical element 110 mainly in the optical-axis direction through the support members 130 and mainly in the directions perpendicular to the optical axis through the elastic members 140 .
- the elastic members 140 that support the dispersed weight of the optical element 110 can minimize the gravity deformations that are not rotationally symmetrical with respect to the optical axis, and reduce the aberration that results from the deformation and positional offset of the optical element 110 , which otherwise deteriorates the imaging performance, and consequently realizing the desired optical performance.
- the elastic member 140 receives the load. However, the elastic member 140 contacts the groove 112 at two points A and B via the forcing surface 142 , and restrains displacements in the optical-axis direction. As a consequence, the optical element 110 becomes high rigid in the acceleration direction, and does not offset in the lateral direction.
- the elastic member 140 may include two members, one for applying an elastic force in the antigravity direction, and the other for applying an elastic force in the direction perpendicular to the antigravity direction.
- FIG. 8 is a schematic block diagram of the inventive illustrative exposure apparatus 200 .
- the exposure apparatus 200 includes, as shown in FIG. 8 , an illumination apparatus 210 for illuminating a mask 220 which forms a circuit pattern, a projection optical system 230 that projects diffracted light created from the illuminated mask pattern onto a plate 240 , and a stage 245 for supporting the plate 240 .
- the exposure apparatus 200 is a projection exposure apparatus that exposes onto the plate 240 a circuit pattern created on the mask 220 , e.g., in a step-and-repeat or a step-and-scan manner.
- Such an exposure apparatus is suitable for a sub-micron or quarter-micron lithography process, and this embodiment exemplarily describes a step-and-scan exposure apparatus (which is also called “a scanner”).
- the step-and-scan manner is an exposure method that exposes a mask pattern onto a wafer by continuously scanning the wafer relative to the mask, and by moving, after a shot of exposure, the wafer stepwise to the next exposure area to be shot.
- the step-and-repeat manner is another mode of exposure method that moves a wafer stepwise to an exposure area for the next shot every shot of cell projection onto the wafer.
- the illumination apparatus 210 illuminates the mask 220 which forms a circuit pattern to be transferred, and includes a light source unit 212 and an illumination optical system 214 .
- the light source unit 212 uses as a light source, for example, as ArF excimer laser with a wavelength of approximately 193 nm, a KrF excimer laser with a wavelength of approximately 248 nm, and F 2 excimer laser with a wavelength of approximately 153 nm, but the a type of laser is not limited to excimer laser and a YAG laser may be, for example. Similarly, the number of laser units is not limited.
- a EUV light source is also applicable. For example, two independently acting solid lasers would cause no coherence between these solid lasers and reduces speckles resulting from the coherence. An optical system for reducing speckles may swing linearly or rotationally.
- a light source applicable to the light source unit 212 is not limited to a laser, and may use one or more lamps such as a mercury lamp and a xenon lamp.
- the illumination optical system 214 is an optical system that illuminates the mask 220 , and includes a lens, a mirror, a light integrator, a stop, and the like, for example, a condenser lens, a fly-eye lens, an aperture stop, a condenser lens, a slit, and an image-forming optical system in this order.
- the illumination optical system 214 can use any light whether it is axial or non-axial light.
- the light integrator may include a fly-eye lens or an integrator formed by stacking two sets of cylindrical lens array plates (or lenticular lenses), and be replaced with an optical rod or a diffractive element.
- the inventive retainer 100 may be used to hold the optical element, such as a lens in the illumination optical system 214 .
- the mask 220 is made, for example, of quartz, forms a circuit pattern (or an image) to be transferred, and is supported and driven by a mask stage (not shown). Diffracted light emitted from the mask 220 passes the projection optical system 230 , thus and then is projected onto the plate 240 .
- the mask 220 and the plate 240 are located in an optically conjugate relationship. Since the exposure apparatus 200 of this embodiment is a scanner, the mask 220 and the plate 240 are scanned at the speed ratio of the reduction ratio of the projection optical system 230 , thus transferring the pattern on the mask 220 to the plate 240 . If it is a step-and-repeat exposure apparatus (referred to as a “stepper”), the mask 220 and the plate 240 stand still in exposing the mask pattern.
- a stepper step-and-repeat exposure apparatus
- the projection optical system 230 may use an optical system solely including a plurality of lens elements, an optical system including a plurality of lens elements and at least one concave mirror (a catadioptric optical system), an optical system including a plurality of lens elements and at least one diffractive optical element such as a kinoform, and a full mirror type optical system, and so on.
- Any necessary correction of the chromatic aberration may use a plurality of lens units made from glass materials having different dispersion values (Abbe values), or arrange a diffractive optical element such that it disperses in a direction opposite to that of the lens unit.
- the inventive retainer 100 may be used to hold the optical element, such as a lens in the projection optical system 230 .
- the retainer 100 is connected to the lens barrel 232 in the projection optical system 230 through the spring member 122 that is provided on the cell member 120 , and may absorb a deformation in a radial direction.
- This structure may prevent the cell member 120 from decentering due to a relative displacement between the lens barrel and the cell member 120 , which relative displacement results from different coefficients of linear expansion between them, when the temperature environment changes, for example, in carrying the apparatus.
- the projection optical system 230 may achieve desired optical performance by reducing the aberration that results from the deformation and positional offset of the optical element 110 which otherwise deteriorates imaging performance.
- the plate 240 is an object to be exposed such as a wafer and a liquid crystal plate, and photoresist is applied onto it.
- a photoresist application step includes a pretreatment, an adhesion accelerator application treatment, a photoresist application treatment, and a pre-bake treatment.
- the pretreatment includes cleaning, drying, etc.
- the adhesion accelerator application treatment is a surface reforming process so as to enhance the adhesion between the photo-resist and a base (i.e., a process to increase the hydrophobicity by applying a surface active agent), through a coat or vaporous process using an organic film such as HMDS (Hexamethyl-disilazane).
- the pre-bake treatment is a baking (or burning) step, softer than that after development, which removes the solvent.
- the stage 245 supports the plate 240 .
- the stage 240 may use any structure known in the art, and a detailed description of its structure and operation is omitted.
- the stage 245 may use, for example, a linear motor to move the plate 240 in XY directions.
- the mask 220 and plate 240 are, for example, scanned synchronously, and the positions of the stage 245 and a mask stage (not shown) are monitored, for example, by a laser interferometer and the like, so that both are driven at a constant speed ratio.
- the stage 245 is installed on a stage stool supported on the floor and the like, for example, via a damper, and the mask stage and the projection optical system 230 are installed on a lens barrel stool (not shown) supported, for example, via a damper to the base frame placed on the floor.
- the projection optical system 230 and/or the illumination optical system 214 used for the exposure apparatus 200 include an optical element held by the inventive retainer 100 , and reduce the deformation and the aberration resulting from the positional offset of the optical element, thus being able to provide high-quality devices (such as semiconductor devices, LCD devices, photographing devices (such as CCDs, etc.), thin film magnetic heads, and the like).
- FIG. 9 is a flowchart for explaining how to fabricate devices (i.e., semiconductor chips such as IC and LSI, LCDs, CCDs, and the like).
- a description will be given of the fabrication of a semiconductor chip as an example.
- Step 1 circuit design
- Step 2 mask fabrication
- Step 3 wafer making
- Step 4 wafer process
- a pretreatment forms actual circuitry on the wafer through lithography using the mask and wafer.
- Step 5 (assembly), which is also referred to as a post-treatment, forms into a semiconductor chip the wafer formed in Step 4 and includes an assembly step (e.g., dicing, bonding), a packaging step (chip sealing), and the like.
- Step 6 (inspection) performs various tests for the semiconductor device made in Step 5 , such as a validity test and a durability test. Through these steps, a semiconductor device is finished and shipped (Step 7 ).
- FIG. 10 is a detailed flowchart of the wafer process in Step 4 .
- Step 11 oxidation
- Step 12 CVD
- Step 13 electrode formation
- Step 14 ion implantation
- Step 15 resist process
- Step 16 exposure
- Step 17 development
- Step 18 etching
- Step 19 resist stripping
- inventive retainer may be used to hold various optical elements, such as a lens, mirror, and filter.
- inventive retainer may be used to hold a mask and a wafer.
- the dispersed stress applied to the optical element may provide a minimum stress to position the optical element in a direction perpendicular to the optical axis of the optical element without breaking the optical element, as well as holding the optical element while restraining its gravity deformation.
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- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Life Sciences & Earth Sciences (AREA)
- Astronomy & Astrophysics (AREA)
- Sustainable Development (AREA)
- Exposure And Positioning Against Photoresist Photosensitive Materials (AREA)
- Mounting And Adjusting Of Optical Elements (AREA)
- Lens Barrels (AREA)
- Exposure Of Semiconductors, Excluding Electron Or Ion Beam Exposure (AREA)
Abstract
A retainer includes a plurality of support members for supporting an optical element, and a plurality of elastic members arranged between the plurality of support members, each elastic member applying an elastic force to the optical element in a direction perpendicular to a gravity direction.
Description
- This application is a continuation of prior application Ser. No. 10/851,955, filed May 21, 2004, the contents of which are hereby incorporated by reference in their entirety.
- This application claims a benefit of foreign priority based on Japanese Patent Application No. 2003-144096, filed on May 21, 2003, which is hereby incorporated by reference herein in its entirety as if fully set forth herein.
- The present invention relates generally to precision machines for mounting an optical element, and more particularly to a projection optical system in an exposure apparatus, etc. The present invention is suitable, for example, for a retainer that holds an optical element for a more precise imaging relationship in an exposure apparatus in projecting and exposing an image on an original sheet, such as a mask or reticle (these terms are used interchangeably in this application) onto an object, such as a single crystal substrate for a semiconductor wafer, a glass plate for a liquid crystal display (LCD). The exposure apparatus is used to fabricate a semiconductor device, an image pick-up device (such as a CCD), and a thin film magnetic head.
- The fabrication of a device using the lithography technique has employed a projection exposure apparatus that uses a projection optical system to project a circuit pattern formed on a mask onto a wafer and the like, thereby transferring the circuit pattern. The projection optical system enables diffracted beams from the circuit pattern to interfere on the wafer and the like, so as to form an image.
- The devices to be mounted on electronic apparatuses should be highly integrated to meet recent demands for miniaturization and low profile of electronic apparatuses, and finer circuit patterns to be transferred or higher resolution have been demanded increasingly. A short wavelength of a light source and an increased numerical aperture (“NA”) in a projection optical system are effective to the high resolution as well as a reduced aberration in the projection optical system.
- An optical element, such as a lens and a mirror, when deforming in an projection optical system causes aberration because an optical path refracts before and after the deformation and light that is supposed to form an image at one point does not converge on one point. The aberration causes a positional offset and short-circuits a circuit pattern on a wafer. On the other hand, a wider pattern size to prevent short-circuiting is contradictory to a fine process.
- Therefore, a projection optical system with small aberration should hold its optical element(s) without changing a shape and a position relative to the optical axis of the optical element in the projection optical system so as to maximize the original optical performance of the optical element. In particular, the projection lens tends to have a larger caliber and a larger lens capacity due to the recent high NA in the projection optical system, and easily deforms by its own weight. In addition, diffraction optical elements, which have been eagerly studied recently, also tend to deform due to its thinness.
- Accordingly, Japanese Patent Application, Publication No. 2001-284226 proposes, as shown in
FIG. 11 , aretainer 1000 that fixes alens 1300 using three or more (e.g., thirty in the embodiment)lens support points 1200 formed on acell 1100, andsprings 1400 for pressing thelens 1300 from a side opposite to thelens support points 1200. A compression force is designed or calculated to the extent that a lens of a low breaking strength, such as a lens made of calcium fluoride (CaF2), does not get damaged. Here,FIG. 11 is an exploded perspective view of the exemplaryconventional retainer 1000. - Similarly, Japanese Patent Application, Publication No. 2001-74991 (corresponding to U.S. Pat. No. 6,239,924) proposes, as shown in
FIG. 12 , aretainer 2000 that fixes a lens installed onto seats on threeflex mount parts 2200 that are radially arranged at regular intervals on an inner circumference on acell 2100, and a spring member with small rigidity in a non-optical axis direction for applying a compression force to the lens from the top of the lens according to the lens shape.Soft mount parts 2300 dispersedly support the lens among theflex mount parts 2200 so as to minimize the gravity deflection and so as not to excessively restrain the positioning of the lens. Here,FIG. 12 is a schematic top transparent view showing the exemplaryconventional retainer 2000. - However, Japanese Patent Application, Publication No. 2001-284226 does not consider the flatness of the
lens support points 1200 and lens deformation. For example, when the heights of thelens support points 1200 deviate, only three points among them supportpoints 1200 even when there are thirty or more lens. Therefore, the portion except the above three support points does not contact the lens but receives forces from thesprings 1400, causing the lens to deform. Thus, this reference has a difficulty in realizing a projection optical system with little aberration due to such a lens's deformation. - On the other hand, Japanese Patent Application, Publication No. 2001-74991 has a careful structure to a lens deformation or distortion, but requires forces opposite to those applied by the flex mount parts at three
flex mount parts 2200 so as to apply a compression force to prevent the lateral offset of the lens. This causes the lens to incur a large load from the spring members of theflex mount parts 2200. This causes the large birefringence and possibly breaks the lens, and has a difficulty in realization. - Accordingly, it is an exemplified object of the present invention to provide a retainer, an exposure apparatus, a device fabrication method which may provide desired optical performance by reducing aberration due to a deformation and a positional offset of an optical element which otherwise deteriorates the imaging performance.
- A retainer according to another aspect of the present invention includes a plurality of support members for supporting an optical element, and a plurality of elastic members arranged between the plurality of support members, each elastic member applying an elastic force to the optical element in a direction perpendicular to the gravity direction.
- An exposure apparatus of another aspect of the present invention includes the above retainer, and an optical system for exposing a pattern formed on a mask or reticle onto an object through the optical element held by the retainer.
- A device fabrication method of another aspect of the present invention includes the steps of exposing a pattern on a mask, onto an object by using the above exposure apparatus, and developing the exposed object.
- Other objects and further features of the present invention will become readily apparent from the following description of the embodiments with reference to accompanying drawings.
-
FIG. 1 is a schematic sectional and perspective view of a retainer of one embodiment according to the present invention applicable to a projection optical system in an exposure apparatus. -
FIG. 2 is an enlarged typical view of principal part of an optical member at its outer circumference side surface as indicated by a broken line A inFIG. 1 . -
FIG. 3 is an enlarged exploded perspective view of a support member shown inFIG. 1 . -
FIG. 4 is a schematic block view of the exemplary exposure apparatus according to the present invention. -
FIG. 5 is an enlarged exploded perspective view of the support member shown inFIG. 1 . -
FIG. 6 is an enlarged exploded perspective view of an elastic member shown inFIG. 1 . -
FIG. 7 is a schematic sectional view showing a contact state between a groove in an optical member and a forcing surface of the elastic member. -
FIG. 8 is a schematic structure of an exemplary inventive exposure apparatus. -
FIG. 9 is a flowchart for explaining how to fabricate devices (such as semiconductor chips such as ICs and LCDs, CCDs, and the like). -
FIG. 10 is a detail flowchart of a wafer process as Step 4 shown inFIG. 9 . -
FIG. 11 is an exploded perspective view of a conventional exemplary retainer. -
FIG. 12 is a schematic top transparent view of another conventional exemplary retainer. - Referring now to accompanying drawings, a description will be given of an
illustrative retainer 100 andexposure apparatus 200 of the present invention. However, the present invention is not limited to these embodiments, and each element may be replaced within a scope of this invention. For example, although theretainer 100 is applied to a projectionoptical system 230 in theexposure apparatus 200 in the instant embodiment, it is applicable to an illuminationoptical system 214 in theexposure apparatus 200 and other known optical systems. Here,FIG. 1 is a schematic sectional and perspective view of the inventive retainer applicable to the projection optical system in theexposure apparatus 200. The gravity direction and the antigravity direction (i.e., a direction opposing to the gravity direction) are parallel to the optical axis of theoptical element 110, as shown in an arrow direction inFIG. 1 . When the optical axis of the optical element is parallel to the gravity and anti-gravity directions, the gravity deformation of the optical element becomes the largest and the gravity deformation often affects the optical performance. Therefore, the instant embodiment applies the present invention to a case where the optical axis of the optical element is parallel to the gravity and anti-gravity directions. - As best shown in
FIG. 1 , theretainer 100 includes acell member 120, thesupport parts 130, and anelastic member 140, and holds theoptical element 110. - The
optical element 110 has a sectionally V-shaped groove 112 on its outer circumference side surface, and is mounted on thesupport parts 130, which will be described later.FIG. 2 is an enlarged typical view of principal part of anoptical member 110 at its outer circumference side surface (or the groove 112) as indicated by a broken line A inFIG. 1 . Theoptical element 110 images light using reflections, refractions, diffractions, etc. Theoptical element 110 includes, for example, a lens, a parallel plate glass, a prism, a mirror, and a Fresnel zone plate, a kinoform, a binary optics, a hologram, and other diffraction optical elements. While the instant embodiment supports theoptical element 110 on thesupport members 130 via thegroove 112, theoptical element 110 may be placed on and supported by thesupport members 130. In placing theoptical element 110 on thesupport members 130, theoptical element 110 is compressed against the side opposite to thesupport members 130 when viewed from the optical element. In addition to thesupport members 130, a compression member is provided to fix a position in an optical-axis (or vertical) direction of theoptical element 110. Thegroove 112 has, but is not limited to, a V-shaped section, and may have a circular section and another shape. - The
cell member 120 mounts threesupport parts 130 for supporting theoptical element 110 at three points, and theelastic member 140, which will be described later. Thecell member 120 is a ring member formed around the optical axis, and made of a material having a coefficient of linear expansion substantially equal to that of theoptical element 110. For example, when theoptical element 110 is a quartz lens, the cell uses a super-inver material. This structure may prevent the external force from deforming or stressing theoptical element 110 via thesupport members 130 and theelastic members 140 due to a relative displacement resulting from different linear expansions between theoptical element 110 and thecell member 120. -
FIG. 3 shows an enlarged exploded perspective view of thesupport part 130 shown inFIG. 1 . Thesupport part 130 has, as shown inFIG. 3 , acontact part 132 for contacting theoptical element 110'sgroove 112 to support theoptical element 110 at three points via thegroove 112. In other words, thesupport part 130 is arranged at three points on thecell member 120 at approximately regular intervals around the optical axis. Thesupport parts 130 are distributed on theoptical element 110 in its circumferential direction at approximately regular intervals, and stably support theoptical element 110. Thecontact part 132 at the tip of thesupport part 130 forms, for example, aspherical absorption member 132 a to support theoptical element 110 and contacts the sectionally V-shapedgroove 112 at its two points as shown inFIG. 4 , without damaging theoptical element 110. Therefore, theoptical element 110 is positioned in the optical-axis (or vertical) direction without being excessively restrained. Here,FIG. 4 is a schematic sectional view showing a contact state between thegroove 112 in theoptical element 110 and theabsorption member 132 a of thesupport member 130. - As shown in
FIG. 5 , three cone-shapedhole 114 each corresponding to thespherical absorption member 132 a may be provided at regular intervals on the outer circumferential side surface of theoptical element 110 to allow theabsorption members 132 a of thesupport member 130 to contact theholes 114. In this case, at least one of threesupport members 130 preferably has the contact part 132 (and theabsorption member 132 a) which includes aspring mechanism 132 b that is deformable in a radial direction of theoptical element 110, in order to avoid deformations of theoptical element 110 due to excessive restraints. Here,FIG. 5 is an enlarged exploded perspective view of thesupport part 130 shown inFIG. 1 . Thesupport part 130 is connected to thecell member 120 via a pin P1. - The
elastic members 140 are provided among threesupport members 130. At least one (preferably plural)elastic members 140 are provided between two adjacent support members along the peripheral part of the optical element. Theelastic members 140 apply an elastic force in the antigravity direction and a direction perpendicular to the antigravity direction. Theelastic member 140 is coupled to thecell member 120 via the pin P2 and the spacer S1 as shown inFIG. 6 . It is preferable that the elastic member elastically deforms in the antigravity or gravity direction (or along an optical-axis direction of the optical element 110), and does not elastically deform in the horizontal direction (or a radial direction of the optical element 110). Alternatively, it is preferable that the elastic member deforms only in a predetermined direction, which is substantially the antigravity or gravity direction (or an optical-axis direction of the optical element 110), or an angle between the predetermined direction and the antigravity or gravity direction is within 5°. Theelastic member 140 is made, for example, of a flat spring.FIG. 6 is an enlarged exploded perspective view of theelastic member 140 shown inFIG. 1 . - The
elastic member 140 has a forcingsurface 142 that has a curvature to contact the sectionally V-shapedgroove 112 in theoptical element 110 and applies an elastic force to theoptical element 110 in the antigravity direction and the direction perpendicular to the antigravity direction. The forcingsurface 142 is formed by bending a tip of the elastic member 140 (i.e., a part that contacts thegroove 112 in the optical element 110) in a pipe shape. Theelastic member 140 is positioned in the optical-axis direction and fixed against thecell member 120 so that two outer circumferential points on the pipe-shaped forcingsurface 142 contact the sectionally V-shapedgroove 112 in theoptical element 110. A position of theelastic member 140 is adjustable by changing the height of thecell member 120 in the optical-axis direction or the height of a spacer in the optical-axis direction, which is provided between thecell member 120 and theelastic member 140. - The elastic member displaces in the gravity direction, and provides the elastic force in the antigravity direction. The
elastic member 140 applies an elastic force to theelastic element 110 in the antigravity direction and the direction perpendicular to the antigravity direction via the contact points A and B, at which theelastic member 140 contacts thegroove 112 in theoptical element 110. At the point A, the elastic force in the antigravity direction, which occurs as theelastic member 140 displaces in the gravity direction, is applied to theoptical element 110 via the forcingsurface 142 after divided into an elastic force A1 in the antigravity direction and an elastic force A2 in the direction perpendicular to the antigravity direction. At the point B, the force necessary for the elastic member 140 (for example, a weight of the optical element 110) to displace in the gravity direction is applied to theoptical element 110 via the forcingsurface 142 after divided by thegroove 112 in theoptical element 110 into an elastic force B1 in the direction perpendicular to the antigravity direction. Here,FIG. 7 is a schematic sectional view showing a contact state between thegroove 112 in theoptical member 110 and the forcingsurface 142 of theelastic member 140. Therefore, the elastic force A1 applied to theoptical element 110 by theelastic member 140 pushes up theoptical element 110 in the antigravity direction, and the elastic forces A2 and B1 applied to theoptical element 110 by theelastic member 140 position theoptical element 110 in a direction perpendicular to the optical-axis direction or a lateral direction. - A sum of the elastic forces A1 applied by the
elastic members 140 is equal to the weight of the optical element. In other words, the gravity deformation of theoptical element 110 can be reduced, if a load F of the elastic force A1 applied by eachelastic member 140 is set so that Equation 1 below is met, where n is the number ofelastic members 140, and M is the weight of theoptical element 110.
F=M/n (1) - Using the above structure, the
retainer 100 positions theoptical element 110 mainly in the optical-axis direction through thesupport members 130 and mainly in the directions perpendicular to the optical axis through theelastic members 140. Theelastic members 140 that support the dispersed weight of theoptical element 110 can minimize the gravity deformations that are not rotationally symmetrical with respect to the optical axis, and reduce the aberration that results from the deformation and positional offset of theoptical element 110, which otherwise deteriorates the imaging performance, and consequently realizing the desired optical performance. - If the
optical element 110 is subject to the acceleration in the direction perpendicular to the optical-axis direction, theelastic member 140 receives the load. However, theelastic member 140 contacts thegroove 112 at two points A and B via the forcingsurface 142, and restrains displacements in the optical-axis direction. As a consequence, theoptical element 110 becomes high rigid in the acceleration direction, and does not offset in the lateral direction. - While the instant embodiment forms the tip of the forcing
surface 142 of theelastic member 140 into a pipe shape, cylindrical or spherical shape would also provide similar effects. While 69elastic members 140 are provided to fill spaces among threesupport members 130, this number is exemplary and at least oneelastic member 140 is provided between twoadjacent support members 130 so that theseelastically members 140 are arranged at regular intervals. Theelastic member 140 may include two members, one for applying an elastic force in the antigravity direction, and the other for applying an elastic force in the direction perpendicular to the antigravity direction. - Referring now to
FIG. 8 , a description will be given of the projectionoptical system 230 to which theinventive retainer 100 is applied and theexposure apparatus 200 having the same. Here,FIG. 8 is a schematic block diagram of the inventiveillustrative exposure apparatus 200. Theexposure apparatus 200 includes, as shown inFIG. 8 , anillumination apparatus 210 for illuminating amask 220 which forms a circuit pattern, a projectionoptical system 230 that projects diffracted light created from the illuminated mask pattern onto aplate 240, and astage 245 for supporting theplate 240. - The
exposure apparatus 200 is a projection exposure apparatus that exposes onto the plate 240 a circuit pattern created on themask 220, e.g., in a step-and-repeat or a step-and-scan manner. Such an exposure apparatus is suitable for a sub-micron or quarter-micron lithography process, and this embodiment exemplarily describes a step-and-scan exposure apparatus (which is also called “a scanner”). “The step-and-scan manner”, as used herein, is an exposure method that exposes a mask pattern onto a wafer by continuously scanning the wafer relative to the mask, and by moving, after a shot of exposure, the wafer stepwise to the next exposure area to be shot. “The step-and-repeat manner” is another mode of exposure method that moves a wafer stepwise to an exposure area for the next shot every shot of cell projection onto the wafer. - The
illumination apparatus 210 illuminates themask 220 which forms a circuit pattern to be transferred, and includes alight source unit 212 and an illuminationoptical system 214. - The
light source unit 212 uses as a light source, for example, as ArF excimer laser with a wavelength of approximately 193 nm, a KrF excimer laser with a wavelength of approximately 248 nm, and F2 excimer laser with a wavelength of approximately 153 nm, but the a type of laser is not limited to excimer laser and a YAG laser may be, for example. Similarly, the number of laser units is not limited. A EUV light source is also applicable. For example, two independently acting solid lasers would cause no coherence between these solid lasers and reduces speckles resulting from the coherence. An optical system for reducing speckles may swing linearly or rotationally. When thelight source unit 212 uses laser, it is desirable to employ a beam shaping optical system that shapes a parallel beam from a laser source to a desired beam shape, and an incoherently turning optical system that turns a coherent laser beam into an incoherent one. A light source applicable to thelight source unit 212 is not limited to a laser, and may use one or more lamps such as a mercury lamp and a xenon lamp. - The illumination
optical system 214 is an optical system that illuminates themask 220, and includes a lens, a mirror, a light integrator, a stop, and the like, for example, a condenser lens, a fly-eye lens, an aperture stop, a condenser lens, a slit, and an image-forming optical system in this order. The illuminationoptical system 214 can use any light whether it is axial or non-axial light. The light integrator may include a fly-eye lens or an integrator formed by stacking two sets of cylindrical lens array plates (or lenticular lenses), and be replaced with an optical rod or a diffractive element. Theinventive retainer 100 may be used to hold the optical element, such as a lens in the illuminationoptical system 214. - The
mask 220 is made, for example, of quartz, forms a circuit pattern (or an image) to be transferred, and is supported and driven by a mask stage (not shown). Diffracted light emitted from themask 220 passes the projectionoptical system 230, thus and then is projected onto theplate 240. Themask 220 and theplate 240 are located in an optically conjugate relationship. Since theexposure apparatus 200 of this embodiment is a scanner, themask 220 and theplate 240 are scanned at the speed ratio of the reduction ratio of the projectionoptical system 230, thus transferring the pattern on themask 220 to theplate 240. If it is a step-and-repeat exposure apparatus (referred to as a “stepper”), themask 220 and theplate 240 stand still in exposing the mask pattern. - The projection
optical system 230 may use an optical system solely including a plurality of lens elements, an optical system including a plurality of lens elements and at least one concave mirror (a catadioptric optical system), an optical system including a plurality of lens elements and at least one diffractive optical element such as a kinoform, and a full mirror type optical system, and so on. Any necessary correction of the chromatic aberration may use a plurality of lens units made from glass materials having different dispersion values (Abbe values), or arrange a diffractive optical element such that it disperses in a direction opposite to that of the lens unit. - The
inventive retainer 100 may be used to hold the optical element, such as a lens in the projectionoptical system 230. Theretainer 100 is connected to the lens barrel 232 in the projectionoptical system 230 through the spring member 122 that is provided on thecell member 120, and may absorb a deformation in a radial direction. This structure may prevent thecell member 120 from decentering due to a relative displacement between the lens barrel and thecell member 120, which relative displacement results from different coefficients of linear expansion between them, when the temperature environment changes, for example, in carrying the apparatus. The projectionoptical system 230 may achieve desired optical performance by reducing the aberration that results from the deformation and positional offset of theoptical element 110 which otherwise deteriorates imaging performance. - The
plate 240 is an object to be exposed such as a wafer and a liquid crystal plate, and photoresist is applied onto it. A photoresist application step includes a pretreatment, an adhesion accelerator application treatment, a photoresist application treatment, and a pre-bake treatment. The pretreatment includes cleaning, drying, etc. The adhesion accelerator application treatment is a surface reforming process so as to enhance the adhesion between the photo-resist and a base (i.e., a process to increase the hydrophobicity by applying a surface active agent), through a coat or vaporous process using an organic film such as HMDS (Hexamethyl-disilazane). The pre-bake treatment is a baking (or burning) step, softer than that after development, which removes the solvent. - The
stage 245 supports theplate 240. Thestage 240 may use any structure known in the art, and a detailed description of its structure and operation is omitted. Thestage 245 may use, for example, a linear motor to move theplate 240 in XY directions. Themask 220 andplate 240 are, for example, scanned synchronously, and the positions of thestage 245 and a mask stage (not shown) are monitored, for example, by a laser interferometer and the like, so that both are driven at a constant speed ratio. Thestage 245 is installed on a stage stool supported on the floor and the like, for example, via a damper, and the mask stage and the projectionoptical system 230 are installed on a lens barrel stool (not shown) supported, for example, via a damper to the base frame placed on the floor. - In exposure, light emitted from the
light source 212, e.g., Koehler-illuminates themask 220 via the illuminationoptical system 214. Light that passes through themask 220 and reflects the mask pattern is imaged onto theplate 240 by the projectionoptical system 230. The projectionoptical system 230 and/or the illuminationoptical system 214 used for theexposure apparatus 200 include an optical element held by theinventive retainer 100, and reduce the deformation and the aberration resulting from the positional offset of the optical element, thus being able to provide high-quality devices (such as semiconductor devices, LCD devices, photographing devices (such as CCDs, etc.), thin film magnetic heads, and the like). - Referring now to
FIGS. 9 and 10 , a description will be given of an embodiment of a device fabrication method using theabove exposure apparatus 200.FIG. 9 is a flowchart for explaining how to fabricate devices (i.e., semiconductor chips such as IC and LSI, LCDs, CCDs, and the like). Here, a description will be given of the fabrication of a semiconductor chip as an example. Step 1 (circuit design) designs a semiconductor device circuit. Step 2 (mask fabrication) forms a mask having a designed circuit pattern. Step 3 (wafer making) manufactures a wafer using materials such as silicon. Step 4 (wafer process), which is also referred to as a pretreatment, forms actual circuitry on the wafer through lithography using the mask and wafer. Step 5 (assembly), which is also referred to as a post-treatment, forms into a semiconductor chip the wafer formed in Step 4 and includes an assembly step (e.g., dicing, bonding), a packaging step (chip sealing), and the like. Step 6 (inspection) performs various tests for the semiconductor device made in Step 5, such as a validity test and a durability test. Through these steps, a semiconductor device is finished and shipped (Step 7). -
FIG. 10 is a detailed flowchart of the wafer process in Step 4. Step 11 (oxidation) oxidizes the wafer's surface. Step 12 (CVD) forms an insulating film on the wafer's surface. Step 13 (electrode formation) forms electrodes on the wafer by vapor disposition and the like. Step 14 (ion implantation) implants ions into the wafer. Step 15 (resist process) applies a photosensitive material onto the wafer. Step 16 (exposure) uses theexposure apparatus 200 to expose a circuit pattern on the mask onto the wafer. Step 17 (development) develops the exposed wafer. Step 18 (etching) etches parts other than a developed resist image. Step 19 (resist stripping) removes disused resist after etching. These steps are repeated, and multi-layer circuit patterns are formed on the wafer. Use of the device fabrication method in this embodiment can manufacture higher-quality devices than the conventional method. - Further, the present invention is not limited to these preferred embodiments and various variations and modifications may be made without departing from the scope of the present invention. For example, the inventive retainer may be used to hold various optical elements, such as a lens, mirror, and filter. The inventive retainer may be used to hold a mask and a wafer.
- According to the inventive retainer, the dispersed stress applied to the optical element may provide a minimum stress to position the optical element in a direction perpendicular to the optical axis of the optical element without breaking the optical element, as well as holding the optical element while restraining its gravity deformation.
Claims (11)
1. A retainer comprising:
a plurality of support members for supporting an optical element; and
a plurality of elastic members arranged among the plurality of support members, each elastic member applying an elastic force to the optical element in a direction perpendicular to a gravity direction.
2. A retainer according to claim 1 , wherein the direction perpendicular to the gravity direction is a radial direction of the optical element.
3. A retainer according to claim 1 , wherein said elastic member applies a compression force to the optical element towards a central of the optical element.
4. A retainer according to claim 2 , wherein said elastic member applies the elastic force to the optical element in a direction opposing to the gravity direction.
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. A retainer according to claim 1 , wherein the optical element is one of a lens, a mirror, and a filter.
10. (canceled)
11. (canceled)
Priority Applications (1)
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US11/265,434 US20060056083A1 (en) | 2003-05-21 | 2005-11-01 | Retainer, exposure apparatus, and device fabrication method |
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JP2003144096A JP2004347814A (en) | 2003-05-21 | 2003-05-21 | Holding device, exposure device, and device manufacturing method |
US10/851,955 US7006308B2 (en) | 2003-05-21 | 2004-05-21 | Retainer, exposure apparatus, and device fabrication method |
US11/265,434 US20060056083A1 (en) | 2003-05-21 | 2005-11-01 | Retainer, exposure apparatus, and device fabrication method |
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JP5026199B2 (en) * | 2007-08-28 | 2012-09-12 | 日立マクセル株式会社 | Lens unit, lens module and camera module |
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JP2016057385A (en) * | 2014-09-08 | 2016-04-21 | 株式会社ケンコー・トキナー | Filter unit |
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US20120049026A1 (en) * | 2010-08-24 | 2012-03-01 | Raytheon Company | Mount for cryogenic fast switching mechanism |
US8919724B2 (en) * | 2010-08-24 | 2014-12-30 | Raytheon Company | Mount for cryogenic fast switching mechanism |
CN104048636A (en) * | 2014-06-12 | 2014-09-17 | 中国科学院长春光学精密机械与物理研究所 | Even supporting device for optical element surface shape detection |
CN107436539A (en) * | 2016-05-25 | 2017-12-05 | 佳能株式会社 | The manufacture method of exposure device and article |
Also Published As
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JP2004347814A (en) | 2004-12-09 |
US7006308B2 (en) | 2006-02-28 |
US20040257679A1 (en) | 2004-12-23 |
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