Abstract:
A system to transfer a pattern from a reticle to a substrate using a lens array having an arbitrarily wide image field that spans the width of the substrate. The disclosed system incorporates multiple, Wynne Dyson lenses arranged in serial pairs and staggered in position so that each dual serial Wynne Dyson lens system transfers a portion of the overall image from the reticle to the substrate as each are transported past the array of lens pairs. To transfer a complete, unbroken pattern on the substrate, each of the dual serial Wynne Dyson lens pairs are positioned in opposing and side-by-side positions and are staggered with respect to the scan direction. Each lens pair optionally includes individual internal adjustments, so that the pattern produced on the substrate does not contain any breaks or discontinuities.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a lens system that has a wide image field, namely, an array of lenses that is structured to have a image field that spans the width of a substrate to be patterned. 
     BACKGROUND OF THE INVENTION 
     Presently there are many situations where it is necessary to pattern substrates that may be 10 to 12 inches wide. With existing lenses a substrate of that width can only be patterned using a multiplicity of scans. To perform such a task with conventional lenses is difficult and slow since in order to do so multiple scans are required using an accurate stage with two dimensional motion capability. 
     In some copy machines an array of graded index fibers have been used to image a long thin area. However, in precision lithographic applications performing imagery in this way is hopelessly crude and not viable. 
     Arrays of tiny lenses that are fabricated as binary optic lenses could be used for this application, but this approach is also impractical in precision applications since these lenses must be very small to limit aberrations thus creating fabrication difficulties that are acute. Additionally, binary optics tend to produce a lot of stray light that also is undesirable in a high resolution optical system. 
     What is needed is an optical system that combines high resolution and a very large contiguous field size without the lens system being extremely large. The Wynne Dyson array of the present invention provides such a lens system with all of those capabilities without being overly large. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a new pattern scanning and projection system to reproduce a pattern from a reticle to a substrate is disclosed. The system of the present invention scans a pattern from a portion of the length of a reticle and projects that scanned pattern onto a corresponding length of a substrate. In that embodiment there is a first carriage to receive and transport the reticle to scan the pattern thereon followed by a pair of Wynne Dyson lens systems in series with each other positioned to receive the scanned pattern as the reticle is transported by the first carriage and to transmit that scanned pattern through the pair of Wynne Dyson lens systems. There is also a second carriage to receive the substrate to provide motion thereto with that motion being provided in synchronization with the transport of the reticle on the first carriage to position the substrate to receive the scanned pattern from the pair of Wynne Dyson lens systems. 
     The present invention can also take on an expanded form by including multiple Wynne Dyson lens pairs arranged to cover the entire width of the reticle. Each lens pair projects a portion of the pattern across the width of the reticle to a corresponding position on the substrate. The field relayed by each Wynne Dyson pair is trapezoidal shaped and positioned so that after scanning, a portion of each field is overlapped with portions of the neighboring fields and therefore the imagery is continuous across the field. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     FIG. 1a is a simplified side view of one dual Wynne Dyson lens system of the present invention. 
     FIG. 1b illustrates the useful field of the Wynne Dyson array of FIG. 1a illustrated relative to the width of the lens array. 
     FIG. 2 illustrates the alignment of the useful fields on the substrate of a plurality of aligned dual Wynne Dyson lens systems as in FIG. 1a. 
     FIG. 3a is a simplified side view of the Wynne Dyson array of the present invention. 
     FIG. 3b is a simplified top view of an array of five dual Wynne Dyson lens systems of the present invention. 
     FIG. 4 is a simplified side view of a second dual Wynne Dyson lens system configuration of the present invention. 
     FIG. 5 is a partial perspective view of an array that utilizes the lens system of FIG. 4. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     There has long been a need for a lithography system with a high throughput and low cost that has the capability of patterning large substrates (e.g. multichip modules, flat panels, etc.). The system of the present invention, as described below and shown in FIG. 4, is a 1× optical system that has a field of about 0.75 inches in width and whatever desired length (e.g. 6, 12 or 22 inches) with a separation between focal planes of only about 7.0 inches, thus making it possible to mount the reticle mask and substrate on a common carriage resulting in a single scan in one direction which in turn yields the desired very high throughput of the system. 
     As will be seen in the following text and accompanying figures, the present invention incorporates a plurality of small dual Wynne Dyson lens systems each employing two Wynne Dyson lenses in series. Then the overall array of the present invention consists of an array of two, or more, Wynne Dyson lens systems to produce a field of the desired width. 
     In FIG. 1a there is shown a side view of the basic dual Wynne Dyson lens system of the present invention. In this view it can be seen that the illumination that passes through reticle 10 strikes first fold mirror 12 and is reflected into the top half of first plano lens 14, continues through the top half of first meniscus lens 16 and is spread over substantially the entire surface of first concave mirror 18. First concave mirror 18 in turn reflects the light striking it to the lower half of first meniscus lens 16, then through the lower half of first plano lens 14, and onto second fold mirror 20 from which the light is reflected downward to the aperture in plate 22. This defines the first Wynne Dyson lens which has a magnification of -1. 
     The second Wynne Dyson lens shown here is the same as the first lens and performs in the same manner. In the second system the light that passes through the aperture in plate 22 is reflected from third fold mirror 24, to the top half of second plano lens 26, proceeds through the top half of second meniscus lens 28 and is then transmitted to substantially the full surface of second concave mirror 30. From the full surface of second concave mirror 30 the light is reflected to the lower half of second meniscus lens 28, progresses through second plano lens 26 to fourth fold mirror 32 from which the light is reflected to substrate 34. Both Wynne Dyson lenses are necessary in the system shown in FIG. 1a if the image on reticle 10 is the image that is to be projected to substrate 34 with the correct orientation for overlapping the image planes. 
     FIG. 1b illustrates the useful field of the dual Wynne Dyson lens system of FIG. 1a. Here the full field size of the lens system is illustrated as circular field 36, which for purposes of illustration has a diameter of 64.0 mm. The useful field is illustrated as trapezoid field 38 with the minimum width thereof being the upper trapezoidal field boundary 40 shown here as being 43.2 mm long resulting in a height of the trapezoid of 16.2 mm. To properly orient the illustration of the view of FIG. 1b with that of FIG. 1a, the upper trapezoidal field boundary 40 of trapezoid field 38 is perpendicular to the page and is furthest from second plano lens 26. Additionally, the plane of FIG. 1b is the plane of substrate 34. Another way to describe the view of FIG. 1b is to say that trapezoid field 38 would be the field on substrate 34 projected back to reticle 10 if one were looking down on reticle 10. 
     Thus it can be seen that in order to project an image from reticle 10 over an elongated field on substrate 34 in a single pass, multiple trapezoidal fields 38, 38&#39;, 38&#34; . . . need to be oriented as illustrated in FIG. 2 as viewed on the surface of substrate 34. 
     Referring next to FIGS. 3a and 3b there is shown a simplified view of an array of dual Wynne Dyson lens systems of the present invention that generates the field pattern on substrate 34 as shown in FIG. 2. To facilitate the recognition of the various dual Wynne Dyson lens systems of the present invention, the component reference numbers have been retained for each additional lens system with a superscript added to those numbers. Additionally to facilitate discussion of the operation of the overall array of the present invention, the right side has been labelled &#34;Array A&#34; and the left side has been labelled &#34;Array B&#34;. In both FIGS. 3a and 3b the direction of scan of both reticle 10 and substrate 34 is illustrated as from left to right. The scan direction could alternately be from right to left. 
     Thus, in FIG. 3a a side view of an array of the dual Wynne Dyson lens systems is illustrated with the second Wynne Dyson lens system shown as a portion of Array B and from FIG. 3b it can further be seen that the second dual Wynne Dyson lens system is staggered with respect to the first such lens system, thus the visible side of the second lens system on the left in FIG. 3a is not in the same plane as the first lens system. From FIG. 3b it can also be seen that upper fold mirror prism 42 is a long rectangular prism that runs the full length of the complete array between first plano lenses 14, 14&#39;, 14&#34;, 14&#39;&#34; and 14 4  with first fold mirror 12 being shared by each of the lens systems that make up Array A, and fold mirror 12&#39; being shared by each of the lens systems in Array B. Note, lower fold mirror prism 44 also runs the full width of the overall array and has the same characteristics as upper fold mirror prism. 
     Further, in FIG. 3b it can be seen that one edge of plano lens 14&#39; is substantially aligned with the centerline of plano lens 14, one edge of each of plano lenses 14 and 14&#34; are substantially aligned with the centerline of plano lens 14&#39;, the second edge of plano lens 14&#39; and one edge of plano lens 14&#39;&#34; are substantially aligned with the centerline of plano lens 14&#34;, and so on. It naturally follows then that these lens systems could be cascaded indefinitely following this pattern. 
     FIG. 4 illustrates a second stacked dual Wynne Dyson five lens element system of the present invention that has a higher numerical aperture than the lens system of FIG. 1a and provides more resolution than the first lens system of FIGS. 3a and 3b. As with the first lens system, illumination is received at the top and passes through reticle 10, strikes first fold mirror 12 and is reflected into the top half of first plano lens 14, and continues through the top half of first meniscus lens 16. At this point two additional lens have been added, a first biconvex lens 46 followed by a third meniscus lens 48 with the illumination continuing through the top half of each of those lenses and from third meniscus lens 48 the illumination is spread over substantially the entire surface of first concave mirror 18. First concave mirror 18 in turn reflects the light striking it to the lower half of third meniscus lens 48, to the lower half of first biconvex lens 46, to the lower half of first meniscus lens 16, then through the lower half of plano lens 14, and onto second fold mirror 20 from which the light is reflected downward to the aperture in plate 22. This defines the first Wynne Dyson lens of the system that utilizes the five element lens system. 
     The second Wynne Dyson lens shown here is the same as the first such lens and performs in the same manner. In the second lens the light that passes through the aperture in plate 22 is reflected from third fold mirror 24, to the top half of second plano lens 26, proceeds through the top half of second meniscus lens 28, to the top half of second biconvex lens 50, to the top half of fourth meniscus lens 52, and is then transmitted to substantially the full surface of second concave mirror 30. From the full surface of second concave mirror 30 the light is reflected to the lower half of fourth meniscus lens 52, to the lower half of second biconvex lens 50, to the lower half of second meniscus lens 28, progresses through second plano lens 26 to fourth fold mirror 32 from which the light is reflected to substrate 34. 
     Additionally, the Wynne Dyson lens system of FIG. 4 includes four glass plates 54, 56, 58 and 60 through which the image passes at various points as it is processed. Small tilts on these plates can be used to adjust the alignment between the different images fields as shown in FIG. 2. 
     FIG. 5 shows a portion of an array of three dual Wynne Dyson lens systems each of which includes dual five lens Wynne Dyson relays of the type described in FIG. 4. Plates 54-60 are also included. Plates 54-60 can perform a variety of functions in this configuration, as well as in any other Wynne Dyson configuration. To insure the alignment of the image delivered to substrate 34 from each of the adjacent similar Wynne Dyson lens system, each of plates 54-60 could be tilted to adjust the individual image position over a small range. The intermediate focal plane provides a convenient place for a shaped aperture to insure that there is a proper overlap of the illuminated fields from each Wynne Dyson lens system. The individual plates 54-60 in any one of the dual Wynne Dyson lens system could also be selectively bent to adjust for a variation in magnification in one Wynne Dyson lens system as compared to each of the others. Similarly, some distortion correction could also be achieved by selectively twisting one or more of plates 54-60 in any of the lens systems. 
     Thus, with this type of array the optical axes, a line connecting corresponding points in the reticle and substrate planes, can be aligned parallel between all lens system modules of the array. Additionally, the focal planes can be made coplanar and the illumination at the extreme of one field can be truncated in such a way that the overlapping fields are not over or under exposed after scanning. Further, the array permits the alignment of individual lens system modules both by employing reasonably tight tolerances when the optical components are manufactured, as well as by the use of the fine adjustments provided for each lens system module with plates 54-60 as discussed above. Additional fine adjustment to make the focal planes of all of the lens system modules coplanar can be achieved by adjusting the axial position of mirrors 18 or 30 within each lens system module. 
     In the scan direction, the magnification of the overall array can be adjusted by advancing or retarding the reticle position slightly in the scan direction as scanning occurs as has been done in the Perkin Elmer Micralign 500/600 series systems. 
     It is also possible to use the present invention to follow an irregular substrate surface (e.g. thin film panel) by individually and dynamically focusing each array module. Focusing can be sensed with a separate air gauge sensor for each lens system module that senses the substrate position. Alternatively, a pair of sensors could be used for each module, one for the reticle and one for the substrate. 
     This configuration also permits the use of a wide variety of illumination systems, the most suitable of which will depend on the overall size of the array. If broad band operation is desirable, then separate (100-200 Watt) lamps could be used for each lens system module. Similarly, a single large lamp with the illumination equally divided and distributed to each lens system module could be used. Additionally, with a mercury lamp illuminated g-h system a light intensity of ≈0.5 Watt/cm 2  is possible in a 0.1 NA system. Assuming a 250 mJ/cm 2  resist sensitive and a 16.2 mm wide slit a 3.24 cm/sec. scan speed is required. Such an illumination system would result in the exposure of an 8.5×11 inch panel in about 9 sec. 
     Advantages of the system of the present invention are that it is completely flexible and can be expanded to any desired length by merely adding additional lens system modules, staggered as shown in FIG. 3b. Thus, very high throughput is possible since only one scan in only one direction is required. 
     There are numerous applications for an array of this type. For example, for multichip modules, flat panels or wafer scanners that have an 8&#34;, 12&#34;, or even greater, capability. It could also be used as an electrostatic copier lens with a resolution of 1000 dots/inch that corresponds to a resolution of 25 μm and requires an NA of only 0.014 assuming an average wavelength of 5000 A°. 
     While the various aspects of the present invention have been described, it is contemplated that persons skilled in the art, upon reading the preceding descriptions and studying the drawings, will realize various alternative approaches to the implementation of the various aspects of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations and modifications that fall within the spirit and scope to the present invention and the appended claims.