1. Field of the Invention
The present invention relates to a stage apparatus and its driving method.
2. Description of the Related Art
An exposure apparatus exposes a pattern of an original (reticle, mask, or the like) onto a photosensitive substrate (wafer, glass plate, or the like where the surface thereof is coated with a resist layer) via a projection optical system in a lithography step included in manufacturing steps for a semiconductor device, a liquid crystal display device, and the like. The exposure apparatus typically includes a stage apparatus that is movable while holding an object which is a substrate or an original. Japanese Patent Laid-Open No. 2003-22960 discloses a stage apparatus having a coarse movement stage which is movable in a long stroke in the X-Y plane direction and a fine movement stage which is mounted on the coarse movement stage and is capable of being driven in small amounts for the positioning with high precision. Here, the top plate of the fine movement stage on which a substrate is placed is positioned in the degree of freedom of six axes (X, Y, Z, ωx, ωy, and ωz) depending on the state of the surface shape of a substrate held thereon and the state of a pattern to be transferred. As an actuator for moving the fine movement stage, linear motors are employed for six axes and electromagnets for pulling the center of gravity are further auxiliary used in the X-axis and Y-axis directions along which a large force is required for acceleration or deceleration.
Each of strokes in the ωx-, ωy-, and ωz-axis which is the rotational direction of each axis of the fine movement stage is determined by the spacing between the coarse movement stage and the fine movement stage (e.g., the spacing between an electromagnet (E-core) on the coarse movement stage side and a magnetic substance (I-core) on the fine movement stage side facing thereto) in the traveling direction. Here, it is preferable that the stroke of the fine movement stage is wide so as to change its orientation as much as possible. The stage spacing needs to be increased in order to increase the stroke. On the other hand, for example, the thrust force of the electromagnet is inversely proportional to the square of the stage spacing on the principle of electromagnetics. In other words, the stage spacing increases with an increase in the stroke of the fine movement stage but a thrust force per unit current of the electromagnet decreases at the increased spacing. Thus, in order to obtain the same (uniform) thrust force even if the stage spacing increases, more current must be fed to the electromagnet, resulting in an increase in the amount of heat generated in the electromagnet.
The present invention provides, for example, a stage apparatus that includes a coarse movement stage and a fine movement stage and is advantageous for reducing the amount of heat generated in an actuator for driving the fine movement stage while ensuring the stroke of the fine movement stage.
According to an aspect of the present invention, a stage apparatus is provided that includes a first stage configured to be movable by a predetermined stroke; a second stage configured to be movable on the first stage by a stroke shorter than the stroke of the first stage; a first driving unit configured to include an actuator which generates a thrust force between the first stage and the second stage and has a different thrust constant depending on the relative positions of the first stage and the second stage and to change the relative position of the second stage with respect to the first stage; a second driving unit configured to change the position of the first stage; and a controller configured to control the first driving unit or the second driving unit such that the relative position of the second stage with respect to the first stage is offset in the direction of movement of the first stage upon acceleration of the first stage whereas the relative position of the second stage with respect to the first stage is offset in a direction opposite to the direction of movement of the first stage upon deceleration of the first stage.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
Firstly, a description will be given of a configuration of a stage apparatus according to a first embodiment of the present invention. The stage apparatus of the present embodiment may be employed as a device that is movable while holding a substrate such as a wafer or an original such as a reticle in a lithography apparatus such as an exposure apparatus or the like. Hereinafter, the stage apparatus of the present embodiment is intended to be a device that is movable while holding a wafer as an exemplary object to be held.
The coarse movement stage 102 is provided with the fine movement stage 103 (to be described below) at the top thereof and moves by a predetermined long stroke on the platen 101. Although not illustrated, a linear motor may be employed as a coarse movement actuator (second driving unit) for driving the coarse movement stage 102.
The fine movement stage 103 includes a top plate 5 having a rectangular plane shape, a base 6, and a fine movement actuator (first driving unit) 7 for causing the top plate 5 to move on the base 6 in the six-axis directions (X, Y, Z, ωx, ωy, and ωz) (change in orientation of the top plate 5). The top plate 5 is provided with (or integrated with) a chuck 8 for holding a wafer by suction for example and performs positioning of the wafer in the six-axis directions while holding it. The base 6 is fixed on the coarse movement stage 102, and both an electromagnet (actuator) of the fine movement actuator 7 to be described below and a stator 4 of the linear motor are provided on the base 6. In the present embodiment, there are two types of the fine movement actuator 7. Firstly, a linear motor is employed as an actuator that performs driving in the Z-axis direction and the tilt (ωx, ωy) direction among the six-axis directions. On the other hand, an electromagnet which is advantageous for suppressing heat generation per unit of thrust force is employed as an actuator that performs driving in the X-axis, Y-axis, and ωz-axis directions along which a thrust force (acceleration force) needs to be imparted to the top plate 5 upon acceleration thereof. Although not illustrated, a reflector plate (mirror) for reflecting light emitted from a laser interferometer is provided on the lateral surface of the top plate 5, and is used as a reference for measuring the position of the top plate 5.
Next, a description will be given of the electromagnet 1 constituting the fine movement actuator 7. The electromagnet 1 includes a coil 11 that produces a magnetic field by the supply of control current and a yoke (E-core) 10 that forms a magnetic path between the yoke (E-core) 10 and a magnetic substance 2 (to be described below) by the produced magnetic field so as to increase a magnetic attraction force, and is fixed in plural (in the present embodiment, six electromagnets 1a to 1f) on the base 6 side. On the other hand, a plurality of magnetic substances (I-cores) 2 (magnetic substances 2a to 2f) corresponding to (in paired with) a plurality of the electromagnets 1a to 1f are provided on the other top plate 5 side. More specifically, a fixing member 9 having a plurality of magnetic substances 2 fixed at a specific spacing on four lateral surfaces thereof is provided on the central area of the backside of the top plate 5 (surface facing the base 6). A plurality of electromagnets 1 is provided so as to face the respective magnetic substances 2 fixed to the fixing member 9. In other words, the fixing member 9 (the top plate 5) is held at an intermediate position on the base 6 as a buoyant object in space surrounded by a plurality of electromagnets 1.
The controller 104 is constituted, for example, by a computer (processor, control substrate including a memory mounted thereon) or the like. The controller 104 generates a driving profile and then control driving of the coarse movement stage 102 and the fine movement stage 103 based on the driving profile. In particular, in the present embodiment, the controller 104 controls driving of the coarse movement stage 102 and the fine movement stage 103 based on different driving profiles. When the stage apparatus 100 is used as a component of, for example, an exposure apparatus, the controller 104 may be integrated with the controller of the exposure apparatus.
Next, a description will be given of the operation of the stage apparatus 100. Firstly, a description will be given of properties relating to spacing between the electromagnet 1 and the magnetic substance 2 shown in
Where “α” represents a constant, “i” represents current fed to the coil 11 of the electromagnet 1, and “d” represents the spacing between the electromagnet 1 and the magnetic substance 2. Here, given that the spacing d is set to 100 μm and the width W of the top plate 5 is set to 500 mm, the stroke (d/(W/2)) of the fine movement stage 103 in the ωz direction is equal to 100/0.250 which is equal to or less than 400 μrad. In order to increase the stroke up to 800 μrad, the spacing d must increase from about 100 μm to 200 μm. However, if the spacing d increases from 100 μm to 200 μm, a thrust constant decreases by about 1/3.5 from 346 N/A to 98 N/A with reference to
Firstly,
Next,
Next,
On the other hand,
Next, a description will be given of a basic operation performed when the stage apparatus 100 is used in, for example, an exposure apparatus.
As described above, the stage apparatus 100 decreases the spacing d between the electromagnet 1 for generating a magnetic attraction force and the magnetic substance 2 during movement of the coarse movement stage 102 and the fine movement stage 103, in particular, upon acceleration or deceleration thereof. In this manner, the electromagnet 1 can be used with a high thrust constant while maintaining the stroke, so that the amount of heat generated in the electromagnet 1 can be suppressed.
In the present embodiment, a driving profile which is an instruction value for the electromagnet 1 is generated in order to decrease the spacing d between the electromagnet 1 and the magnetic substance 2 upon acceleration or deceleration. As a driving profile, for example, an acceleration profile or a magnetic flux profile calculated from the acceleration profile may be used. Furthermore, magnetic flux feedback control may also be performed.
In the present embodiment, the fine movement stage 103 is driven instead of the coarse movement stage 102 when the spacing d between the electromagnet 1 and the magnetic substance 2 decreases. This is because the fine movement stage 103 has a wide control band so that high speed positioning can be achieved with high precision as compared with the coarse movement stage 102. However, in the present invention, a driving profile which is an instruction value for a coarse movement actuator may also be generated in order to decrease the spacing d between the electromagnet 1 and the magnetic substance 2 upon acceleration or deceleration. As a driving profile, for example, an acceleration profile or a position profile calculated from the acceleration profile may be used. Furthermore, position feedback control may also be performed.
In the present embodiment, the linear motor of the fine movement actuator 7 performs driving in the Z-axis direction and the tilt (ωx, ωy) direction but may also perform driving in the six-axis direction. In this case, a driving profile which is an instruction value for the linear motor of the fine movement actuator 7 may also be generated in order to decrease the spacing d between the electromagnet 1 and the magnetic substance 2 upon acceleration or deceleration. As a driving profile, for example, an acceleration profile or a position profile calculated from the acceleration profile may be used. Furthermore, position feedback control may also be performed.
Also in the present embodiment, the spacing d is positively changed upon acceleration or deceleration but the thrust constant of the electromagnet 1 varies depending on the width (size) of the spacing d, and thus, the controller 104 needs to switch an electromagnet control gain as appropriate. It is preferable that the thrust constant for the spacing d of the single electromagnet 1 is measured in advance using a jig and then the controller 104 performs correction using the measurement value. As can be seen from Formula (1), the measurement value is inversely proportional to the square of the spacing d. Hence, the controller 104 may hold the measurement value as a correction function by the spacing d or may also hold the measurement value as a correction table for the spacing d.
In order to favorably control the spacing d, it is preferable that the stage apparatus 100 includes a sensor (measuring unit) 20 for directly measuring the spacing d as shown in
The method for driving the stage apparatus of the present embodiment includes a step (first generating step) of generating a driving profile of the first driving unit (electromagnet or linear motor of fine movement actuator) or the second driving unit (coarse movement actuator) such that the relative position of the fine movement stage with respect to the coarse movement stage is offset in the direction of movement of the coarse movement stage upon acceleration thereof; a step (second generating step) of generating a driving profile of the first driving unit (electromagnet or linear motor of fine movement actuator) or the second driving unit (coarse movement actuator) such that the relative position of the fine movement stage with respect to the coarse movement stage is offset in a direction opposite to the direction of movement of the coarse movement stage upon deceleration thereof; and a step of controlling the first driving unit or the second driving unit based on the driving profiles generated in the first and second generating steps.
As described above, according to the present embodiment, a stage apparatus that includes a coarse movement stage and a fine movement stage and is advantageous for reducing the amount of heat generated in an actuator for driving the fine movement stage while ensuring the stroke of the fine movement stage may be provided.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2013-182874 filed on Sep. 4, 2013, and Japanese Patent Application No. 2014-156173 filed on Jul. 31, 2014, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2013-182874 | Sep 2013 | JP | national |
2014-156173 | Jul 2014 | JP | national |