Movable body apparatus, exposure apparatus, manufacturing method of flat-panel display and device manufacturing method, and movement method of object

A substrate stage device that moves a substrate has: a noncontact holder that supports the substrate in a noncontact manner; a first drive section that moves the noncontact holder; scale plates that serve as a reference of movement of the noncontact holder; a first measurement section that has scale plates and Y heads, one of the scale plates and the Y heads being provided at the noncontact holder and the other of the scale plates and the Y heads being provided between the scale plates and the noncontact holder, and that measures position information of the Y heads; a second measurement section that measures position information of the other of the scale plates and the Y heads; and a position measurement system that obtains position information of the noncontact holder on the basis of the position information measured by the first and the second measurement sections.

TECHNICAL FIELD

The present invention relates to movable body apparatuses, exposure apparatuses, manufacturing methods of flat-panel displays and device manufacturing methods, and movement methods of objects, and more particularly to a movable body apparatus and a movement method for moving an object, an exposure apparatus including the movable body apparatus, a manufacturing method of flat-panel displays or a device manufacturing method using the exposure apparatus.

BACKGROUND ART

Conventionally, in a lithography process for manufacturing electronic devices (micro devices) such as liquid crystal display devices and semiconductor devices (integrated circuits and the like), used are exposure apparatuses such as an exposure apparatus of a step-and-scan method (a so-called scanning stepper (which is also called a scanner)) that, while synchronously moving a mask or a reticle (hereinafter, generically referred to as a “mask”) and a glass plate or a wafer (hereinafter, generically referred to as a “substrate”) along a predetermined scanning direction, transfers a pattern formed on the mask onto the substrate using an energy beam.

As this type of exposure apparatuses, such an exposure apparatus is known that is equipped with an optical interferometer system that obtains position information of a substrate serving as an exposure target, within a horizontal plane, using a bar mirror (a long mirror) that a substrate stage device has (e.g., refer to PTL 1).

Here, in the case of obtaining position information of a substrate using the optical interferometer system, the influence of so-called air fluctuation cannot be ignored.

CITATION LIST

Patent Literature

SUMMARY OF INVENTION

According to a first aspect of the present invention, there is provided a movable body apparatus, comprising: a support section that supports an object in a noncontact manner; a holding section that holds the object supported in a noncontact manner by the support section; a first drive section that moves the holding section in a first direction and a second direction intersecting each other; a reference member serving as a reference of movement of the holding section in the first and the second directions; a first measurement section having a first grating section that has a measurement component in the first direction and a first head that is disposed to face the first grating section and irradiates the first grating section with a measurement beam, the first measurement section measuring position information of the first head by the first head and the first grating section, one of the first grating section and the first head being provided at the holding section and the other of the first grating section and the first head being provided between the reference member and the holding section; a second measurement section that measures position information of the other of the first grating section and the first head; and a position measurement system that obtains position information, in the first and the second directions, of the holding section that holds the object, based on the position information measured by the first and the second measurement sections.

According to a second aspect of the present invention, there is provided an exposure apparatus, comprising: the movable body apparatus related to the first aspect; and a pattern forming device that forms a predetermined pattern on the object using an energy beam.

According to a third aspect of the present invention, there is provided a manufacturing method of a flat-panel display, comprising: exposing the object using the exposure apparatus related to the second aspect; and developing the object that has been exposed.

According to a fourth aspect of the present invention, there is provided a device manufacturing method, comprising: exposing the object using the exposure apparatus related to the second aspect; and developing the object that has been exposed.

According to a fifth aspect of the present invention, there is provided a movement method of an object, comprising: supporting an object in a noncontact manner, by a support section; holding the object supported in a noncontact manner by the support section, by a holding section; moving the holding section in a first direction and a second direction intersecting each other, by a first drive section; by a first measurement section having a first grating section that has a measurement component in the first direction and a first head that is disposed to face the first grating section and irradiates the first grating section with a measurement beam, measuring position information of the first head using the first head and the first grating section, one of the first grating section and the first head being provided at the holding section and the other of the first grating section and the first head being provided between a reference member and the holding section, and the reference member serving as a reference of movement of the holding section in the first and the second directions; measuring position information of the other of the first grating section and the first head, by a second measurement section; and obtaining position information, in the first and the second directions, of the holding section that holds the object, based on the position information measured by the first and the second measurement sections.

DESCRIPTION OF EMBODIMENTS

First Embodiment

A first embodiment will be described below, usingFIGS. 1 to 10b.

FIG. 1schematically shows the configuration of a liquid crystal exposure apparatus10related to the first embodiment. Liquid crystal exposure apparatus10is a projection exposure apparatus of a step-and-scan method, which is a so-called scanner, with a rectangular (square) glass substrate P (hereinafter, simply referred to as a substrate P) used in, for example, a liquid crystal display device (a flat-panel display) or the like, serving as an object to be exposed.

Liquid crystal exposure apparatus10has: an illumination system12; a mask stage14to hold a mask M on which patterns such as a circuit pattern are formed; a projection optical system16; an apparatus main body18; a substrate stage device20to hold substrate P whose surface (a surface facing the +Z side inFIG. 1) is coated with resist (sensitive agent); a control system thereof; and the like. Hereinafter, the explanation is given assuming that a direction in which mask M and substrate P are each scanned relative to projection optical system16at the time of exposure is an X-axis direction, a direction orthogonal to the X-axis within a horizontal plane is a Y-axis direction, and a direction orthogonal to the X-axis and the Y-axis is a Z-axis direction. Further, the explanation is given assuming that rotation directions around the X-axis, the Y-axis and the Z-axis are a θx direction, a θy direction and a θz direction, respectively.

Illumination system12is configured similarly to an illumination system disclosed in, for example, U.S. Pat. No. 5,729,331 and the like. That is, illumination system12irradiates mask M with light emitted from a light source (not illustrated) (e.g. a mercury lamp), as illumination light for exposure (illumination light) IL, via a reflection mirror, a dichroic mirror, a shutter, a wavelength selecting filter, various types of lenses and the like (none of which are illustrated). As illumination light IL, light such as, for example, an i-line (with wavelength of 365 nm), a g-line (with wavelength of 436 nm), and an h-line (with wavelength of 405 nm) (or synthetic light of the i-line, the g-line and the h-line described above) is used.

Mask stage14holds mask M of a light-transmitting type. Main controller50(seeFIG. 6) drives mask stage14(i.e. mask M) with a predetermined long stroke relative to illumination system12(illumination light IL) in the X-axis direction (the scanning direction), and also finely drives mask stage14in the Y-axis direction and the θz direction, via a mask stage drive system52(seeFIG. 6) including, for example, a liner motor. Position information of mask stage14within the horizontal plane is obtained by a mask stage position measurement system54(seeFIG. 6) including, for example, a laser interferometer.

Projection optical system16is disposed below mask stage14. Projection optical system16is a so-called multi-lens type projection optical system having a configuration similar to a projection optical system disclosed in, for example, U.S. Pat. No. 6,552,775 and the like, and projection optical system16is equipped with a plurality of optical systems that are, for example, both-side telecentric and form erected normal images. An optical axis AX of illumination light IL projected on substrate P from projection optical system16is parallel to the Z-axis.

In liquid crystal exposure apparatus10, when mask M located in an illumination area is illuminated with illumination light IL from illumination system12, by illumination light IL that has passed through mask M, a projected image of a pattern (a partial image of the pattern) of mask M within the illumination area is formed on an exposure area on substrate P, via projection optical system16. Then, mask M is moved relative to the illumination area (illumination light IL) in the scanning direction and also substrate P is moved relative to the exposure area (illumination light IL) in the scanning direction, and thereby the scanning exposure of one shot area on substrate P is performed and the pattern formed on mask M (the entire pattern corresponding to the scanning range of mask M) is transferred onto the shot area. Here, the illumination area on mask M and the exposure area (an irradiation area of the illumination light) on substrate P are in a relationship optically conjugate with each other by projection optical system16.

Apparatus main body18is a section that supports mask stage14and projection optical system16that are described above, and is installed on a floor F of a clean room via a plurality of vibration isolating devices18d. Apparatus main body18is configured similarly to an apparatus main body as disclosed in, for example, U.S. Patent Application Publication No. 2008/0030702, and apparatus main body18has: an upper mount section18a(which is also referred to as an optical surface plate) that supports projection optical system16described above; a pair of lower mount sections18b(one of which is not illustrated inFIG. 1because the pair of lower mount sections18boverlap in a depth direction of the paper surface. SeeFIG. 2); and a pair of middle mount sections18c.

Substrate stage device20is a section that performs the high accuracy positioning of substrate P relative to projection optical system16(illumination light IL), and substrate stage device20drives substrate P with a predetermined long stroke along the horizontal plane (the X-axis direction and the Y-axis direction), and also finely drives substrate P in directions of six degrees of freedom. Substrate stage device20is equipped with a base frame22, a coarse movement stage24, a weight cancelling device26, an X guide bar28, a substrate table30, a noncontact holder32, a pair of auxiliary tables34, a substrate carrier40and the like.

Base frame22is equipped with a pair of X beams22a. X beam22ais made up of a member with a rectangular YZ cross-sectional shape extending in the X-axis direction. The pair of X beams22aare disposed at a predetermined spacing in the Y-axis direction, and the pair of X beams22are each installed on floor F via a leg section22b, in a state of being physically separated (vibrationally isolated) from apparatus main body18. Each of the pair of X beams22aand each of leg sections22bare integrally coupled by a coupling member22C.

Coarse movement stage24is a section for driving substrate P with a long stroke in the X-axis direction, and coarse movement stage24is equipped with a pair of X carriages24a, corresponding to the pair of X beams22adescribed above. X carriage24ais formed into an inversed L-like YZ cross-sectional shape, and is placed on the corresponding X beam22avia a plurality of mechanical linear guide devices24c.

The pair of X carriages24aare synchronously driven with a predetermined long stroke in the X-axis direction (about 1 time to 1.5 times the length of substrate P in the X-axis direction) along the respective corresponding X beams22a, by main controller50(seeFIG. 6) via an X linear actuator that is a part of a substrate table drive system56(seeFIG. 6) for driving substrate table30. The type of the X linear actuator for driving X carriage24acan be changed as needed. InFIG. 2, for example, a linear motor24dincluding a mover that X carriage24ahas and a stator that the corresponding X beam22ahas is used, but this is not intended to be limiting, and for example, a feed screw (a ball screw) device or the like may be used.

Further, as illustrated inFIG. 2, coarse movement stage24has a pair of Y stators62a. Y stators62aare made up of members extending in the Y-axis direction (seeFIG. 1). One of Y stators62aand the other of Y stators62abridge on the pair of X carriages24a, respectively, at the +X side end vicinity part of coarse movement stage24and the −X side end vicinity part of coarse movement stage24a(seeFIG. 1). The functions of Y stators62awill be described later.

Weight cancelling device26is inserted between the pair of X carriages24athat coarse movement stage24has, and supports the empty weight of a system including substrate table30and noncontact holder32, from below. Since the details of weight cancelling device26are disclosed in, for example, U.S. Patent Application Publication No. 2010/0018950, the description thereof will be omitted. Weight cancelling device26is mechanically coupled to coarse movement stage24, via a plurality of coupling devices26a(which are also referred to as flexure devices) radially extending from weight cancelling device26, and weight cancelling device26is towed by coarse movement stage24, thereby being moved integrally with coarse movement stage24in the X-axis direction. Note that, although weight cancelling device26is to be coupled to coarse movement stage24via coupling devices26aradially extending from weight cancelling device26, such a configuration may also be employed that weight cancelling device26is coupled by coupling devices26aextending in the X direction in order to be moved only in the X-axis direction.

X guide bar28is a section that functions as a surface plate when weight cancelling device26is moved. X guide bar28is made up of a member extending in the X-axis direction, and as illustrated inFIG. 1, X guide bar28is inserted between the pair of X beams22athat base frame22has, and is fixed on the pair of lower mount sections18bthat apparatus main body18has. The center of X guide bar28in the Y-axis direction substantially coincides with the center of the exposure area generated on substrate P by illumination light IL in the Y-axis direction. The upper surface of X guide bar28is set parallel to the XY plane (the horizontal plane). Weight cancelling device26described above is placed on X guide bar28in a noncontact state, for example, via air bearings26b. When coarse movement stage24is moved in the X-axis direction on base frame22, weight cancelling device26is moved in the X-axis direction on X guide bar28.

Substrate table30is made up of a plate-like (or box-like) member having a rectangular shape with the X-axis direction serving as a longitudinal direction in planar view,5and as illustrated inFIG. 2, is supported in a noncontact manner from below by weight cancelling device26in a state where the central part is freely swingable with respect to the XY plane via a spherical bearing device26c. Further, as illustrated inFIG. 1, the pair of auxiliary tables34(not 10 illustrated inFIG. 2) are coupled to substrate table30. The functions of the pair of auxiliary tables34will be described later.

Referring back toFIG. 2, substrate table30is finely driven as needed relative to coarse movement stage24, in directions intersecting the horizontal plane (the XY plane), i.e., the Z-axis direction, the θx direction and the θy direction (hereinafter, referred to Z-tilt directions), by a plurality of linear motors30a(e.g. voice coil motors) that are a part of substrate table drive system56(seeFIG. 6) and include stators that coarse movement stage24has and movers that substrate table30itself has.

Substrate table30is mechanically coupled to coarse movement stage24via a plurality of coupling devices30b(flexure devices) radially extending from substrate table30. Coupling devices30binclude, for example, boll joints, and are arranged so as not to block the relative movement of substrate table30with a fine stroke in the Z-tilt directions with respect to coarse movement stage24. Further, in the case when coarse movement stage24is moved with a long stroke in the X-axis direction, substrate table30is towed by coarse movement stage24via the plurality of coupling devices30b, and thereby coarse movement stage24and substrate table30are integrally moved in the X-axis direction. Note that, since substrate table30is not moved in the Y-axis direction, substrate table30may be coupled to coarse movement stage24via a plurality of coupling devices30bparallel to the X-axis direction, instead of coupling devices30bradially extending to coarse movement stage24.

Noncontact holder32is made up of a plate-like (or box-like) member having a rectangular shape with the X-axis direction serving as a longitudinal direction in planar view, and supports substrate P from below with its upper surface. Noncontact holder32has a function of preventing the sag, wrinkle or the like of substrate P from being generated (of performing flatness correction of substrate P). Noncontact holder32is fixed to the upper surface of substrate table30, and is moved with a long stroke integrally with substrate table30described above in the X-axis direction and is also finely moved in the Z-tilt directions.

The length of each of the four sides of the upper surface (the substrate supporting surface) of noncontact holder32is set substantially the same as (actually, slightly shorter than) the length of each of the four sides of substrate P. Consequently, noncontact holder32can support substantially the entirety of substrate P from below, or more specifically, can support an area to be exposed on substrate P (an area excluding margin areas that are formed at the end vicinity parts of substrate P) from below.

A pressurized gas supply device and a vacuum suction device (not illustrated) that are installed external to substrate stage device20are coupled to noncontact holder32via piping members such as, for example, tubes. Further, a plurality of minute hole sections that communicate with the piping members referred to above are formed on the upper surface (the substrate placing surface) of noncontact holder32. Noncontact holder32blows out the pressurized gas (e.g. the compressed air) supplied from the pressurized gas supply device described above to the lower surface of substrate P via (apart of) the hole sections, thereby levitating substrate P. Further, together with the blowing-out of the pressurized gas described above, noncontact holder32suctions the air between the lower surface of substrate P and the substrate supporting surface by a vacuum suction force supplied from the vacuum suction device described above. Accordingly, the load (the preload) acts on substrate P, and the flatness correction of substrate P is performed along the upper surface of noncontact holder32. However, the relative movement of substrate P and noncontact holder32in directions parallel to the horizontal plane is not blocked because a gap is formed between substrate P and noncontact holder32.

Substrate carrier40is a section that holds substrate P, and moves substrate P relative to illumination light IL (seeFIG. 1) in directions of three degrees of freedom within the horizontal plane (the X-axis direction, the Y-axis direction and the θz direction). Substrate carrier40is formed into a rectangular frame-like (a picture-frame-like) shape in planar view, and is moved relative to noncontact holder32along the XY plane in a state of holding the areas (the margin areas) at the end vicinity parts (the outer periphery edges) of substrate P. The details of substrate carrier40will be described below usingFIG. 3.

As illustrated inFIG. 3, substrate carrier40is equipped with a pair of X frames42xand a pair of Y frames42y. The pair of X frames42xare each made up of a tabular member extending in the X-axis direction, and are disposed at a predetermined spacing in the Y-axis direction (the spacing wider than the size of substrate P and the size of noncontact holder32in the Y-axis direction). Further, the pair of Y frames42yare each made up of a tabular member extending in the Y-axis direction, and are disposed at a predetermined spacing in the X-axis direction (the spacing wider than the size of substrate P and the size of noncontact holder32in the X-axis direction).

Y frame42yon the +X side is coupled, via a spacer42s, to the lower surface of the +X side end vicinity part of each of the pair of X frames42x. Similarly, Y frame42yon the −X side is coupled, via a spacer42s, to the lower surface of the −X side end vicinity part of each of the pair of X frames42x. Accordingly, the height positions (the positions in the Z-axis direction) of the upper surfaces of the pair of Y frames42yare set lower (on the −Z side) than the height positions of the lower surface of the pair of X frames42x.

Further, on the lower surface of each of the pair of X frames42x, a pair of adsorption pads44are attached, spaced apart from each other in the X-axis direction. Consequently, substrate carrier40has, for example, four adsorption pads44in total. Adsorption pads44are disposed protruding from the surfaces of the pair of X frames42xfacing each other, toward directions opposing to each other (the inner sides of substrate carrier40). For example, the positions of the four adsorption pads44within the horizontal plane (the attached positions with respect to X frames42x) are set so that the four adsorption pads44can support the four corner vicinity parts (the margin areas) of substrate P from below in a state where substrate P is inserted between the pair of X frames42x. For example, a vacuum suction device (not illustrated) is coupled to each of the four adsorption pads44. Adsorption pads44adsorb and hold the lower surface of substrate P by vacuum suction forces supplied from the vacuum suction devices descried above. Note that the number of adsorption pads44is not limited to four, but can be changed as needed.

Here, as illustrated inFIG. 2, in a state where noncontact holder32and substrate carrier40are combined, the four corner vicinity parts of substrate P are supported (held by adsorption) from below by adsorption pads44that substrate carrier40has, and also the substantially entire surface including the central part of substrate P is supported from below by noncontact holder32in a noncontact manner. In this state, the +X side end and the −X side end of substrate P protrude from the +X side end and the −X side end of noncontact holder32, and for example, the four adsorption pads44(a part of which is not illustrated inFIG. 2) adsorb and hold the portions of substrate P protruding from noncontact holder32. That is, the attached positions of adsorption pads44with respect to X frames42xare set so that adsorption pads44are located on the outer side with respect to noncontact holder32in the X-axis direction.

Next, a substrate carrier drive system60(seeFIG. 6) for driving substrate carrier40will be described. In the present embodiment, main controller50(seeFIG. 6) drives substrate carrier40with a long stroke relative to noncontact holder32in the Y-axis direction and also finely drives substrate carrier40in the directions of three degrees of freedom within the horizontal plane, via substrate carrier drive system60. Further, main controller50drives noncontact holder32and substrate carrier40integrally (synchronously) in the X-axis direction via substrate table drive system56described above (seeFIG. 6) and substrate carrier drive system60.

As illustrated inFIG. 2, substrate carrier drive system60is equipped with a pair of Y linear actuators62that include Y stators62athat coarse movement stage24described above has and Y movers62bthat work with Y stators62ato generate thrust forces in the Y-axis direction. As illustrated inFIG. 4, a Y stator64aand an X stator66aare attached to Y mover62bof each of the pair of Y linear actuators62.

Y stator64aworks with a Y mover64battached to substrate carrier40(the lower surface of Y frame42y), to configure a Y voice coil motor64that applies a thrust force in the Y-axis direction to substrate carrier40. Further, X stator66aworks with an X mover66battached to substrate carrier40(the lower surface of Y frame42y), to configure an X voice coil motor66that applies a thrust force in the X-axis direction to substrate carrier40. In this manner, substrate stage device20has one each of Y voice coil motor64and X voice coil motor66on each of the +X side and the −X side of substrate carrier40.

Here, on the +X side and the −X side of substrate carrier40, Y voice coil motors64and X voice coil motors66are each disposed point-symmetric with respect to the gravity center position of substrate P. Consequently, when causing the thrust force in the X-axis direction to act on substrate carrier40using X voice coil motor66on the −X side of substrate carrier40and X voice coil motor66on the +X side of substrate carrier40, the effect similar to that of causing the thrust force in parallel to the X-axis direction to act on the gravity center position of substrate P can be obtained, that is, the moment in the θz direction can be suppressed from acting on substrate carrier40(substrate P). Note that since the pair of Y voice coil motors64are disposed with the gravity center (line) of substrate Pin the X-axis direction in between, the moment in the θz direction does not act on substrate carrier40.

Substrate carrier40is finely driven relative to coarse movement stage24(i.e. noncontact holder32) in the directions of three degrees of freedom within the horizontal plane, by main controller50(FIG. 6) via the pair of Y voice coil motors64and the pair of X voice coil motors66described above. Further, when coarse movement stage24(i.e. noncontact holder32) is moved with a long stroke in the X-axis direction, main controller50applies the thrust force in the X-axis direction to substrate carrier40using the pair of X voice coil motors66described above so that noncontact holder32and substrate carrier40are integrally moved with a long stroke in the X-axis direction.

Further, main controller50(seeFIG. 6) relatively moves substrate carrier40with a long stroke with respect to noncontact holder32in the Y-axis direction, using the pair of Y linear actuators62and the pair of Y voice coil motors64described above. More specifically, while moving Y movers62bof the pair of Y linear actuators62in the Y-axis direction, main controller50causes the thrust force in the Y-axis direction to act on substrate carrier40using Y voice coil motors64including Y stators64aattached to Y movers62b. Accordingly, substrate carrier40is moved with a long stroke in the Y-axis direction, independently (separately) from noncontact holder32.

In this manner, in substrate stage device20of the present embodiment, substrate carrier40that holds substrate P is moved with a long stroke integrally with noncontact holder32in the X-axis (scanning) direction, whereas substrate carrier40is moved with a long stroke independently from noncontact holder32in the Y-axis direction. Note that, although the Z-positions of adsorption pads44and the Z-position of noncontact holder32are partially overlap as can be seen fromFIG. 2, there is no risk that adsorption pads44and noncontact holder32come into contact with each other because it is only the Y-axis direction in which substrate carrier40is relatively moved with a long stroke with respect to noncontact holder32.

Further, in the case of driving substrate table30(i.e. noncontact holder32) in the Z-tilt directions, substrate P whose flatness has been corrected along noncontact holder32changes in attitude together with noncontact holder32in the Z-tilt directions, and therefore substrate carrier40that adsorbs and holds substrate P changes in attitude together with substrate P in the Z-tilt directions. Note that the attitude of substrate carrier40may be prevented from changing, by to the elastic deformation of adsorption pads44.

Referring back toFIG. 1, the pair of auxiliary tables34are devices that work with noncontact holder32to support the lower surface of substrate P held by substrate carrier40, and substrate carrier40(X frames42x), when substrate carrier40is relatively moved in the Y-axis direction separately from noncontact holder32. As is described above, substrate carrier40is relatively moved with respect to noncontact holder32in a state of holding substrate P, and therefore, for example, when substrate carrier40is moved in the +Y direction from the state illustrated inFIG. 1, the +Y side end vicinity part of substrate P is no longer supported by noncontact holder32. Therefore, in substrate stage device20, in order to suppress the bending due to the self-weight of a portion, of substrate P, that is not supported by noncontact holder32, substrate P is supported from below using one of the pair of auxiliary tables34. The pair of auxiliary tables34have substantially the same structure, except that they are disposed laterally symmetric on the page surface.

As illustrated inFIG. 3, auxiliary table34has a plurality of air levitation units36. Note that such a configuration is employed in the present embodiment that air levitation unit36is formed into a bar-like shape extending in the Y-axis direction, and the plurality of air levitation units36are disposed at a predetermined spacing in the X-axis direction. However, the shape, the number, the arrangement and the like of air levitation units36are not limited in particular, as far as the bending of substrate P due to the self-weight can be suppressed. As illustrated inFIG. 4, the plurality of air levitation units36are supported from below by arm-like support members36aprotruding from the side surfaces of substrate table30. A minute gap is formed between the plurality of air levitation units36and noncontact holder32.

The height positions of the upper surfaces of air levitation units36are set substantially the same as (or slightly lower than) the height position of the upper surface of noncontact holder32. Air levitation units36support substrate P in a noncontact manner by blowing out gas (e.g. air) from the upper surface of air levitation units36to the lower surface of substrate P. Note that, although noncontact holder32described above performs the flatness correction of substrate P by causing the preload to act on substrate P, air levitation units36only have to suppress the bending of substrate P, and therefore air levitation units36should only supply the gas to the lower surface of substrate P and do not have to control in particular the height position of substrate P on air levitation units36.

Next, a substrate position measurement system70(seeFIG. 6) for measuring position information of substrate P (substrate carrier40) in the directions of six degrees of freedom will be described. Substrate position measurement system70of the present embodiment has a pair of head units72, as illustrated inFIG. 1. One head unit72is disposed on the −Y side of projection optical system16, while the other head unit72is disposed on the +Y side of projection optical system16.

Each of the pair of head units72obtains position information of substrate P within the horizontal plane (position information in X-axis direction and the Y-axis direction, and rotation amount information in the θz direction), using reflection-type diffraction gratings that substrate carrier40has. Corresponding to the pair of head units72, a plurality (e.g. six inFIG. 3) of scale plates46are pasted on the upper surface of each of the pair of X frames42xof substrate carrier40, as illustrated inFIG. 3. Scale plate46is a member with a band-like shape in planar view extending in the X-axis direction. The length of scale plate46in the X-axis direction is shorter, compared to the length of X frame42xin the X-axis direction, and the plurality of scale plates46are arrayed at a predetermined spacing (spaced apart from each other) in the X-axis direction.

FIG. 5shows X frame42xon the −Y side and head unit72corresponding thereto. On each of the plurality of scale plates46fixed on X frame42x, an X scale48xand a Y scale48yare formed. X scale48xis formed in the −Y side half area of scale plate46, while Y scale48yis formed in the +Y side half area of scale plate46. X scale48xhas a reflection-type X diffraction grating, and Y scale48yhas a reflection-type Y diffraction grating. Note that inFIG. 5, in order to facilitate the understanding, a spacing (a pitch) between a plurality of grid lines that form X scale48xand Y scale48yis illustrated wider than the actual spacing (the actual pitch).

As illustrated inFIG. 4, head unit72is equipped with: a Y linear actuator74; a Y slider76that is driven with a predetermined stroke relative to projection optical system16(seeFIG. 1) in the Y-axis direction, by Y linear actuator74; and a plurality of measurement heads (X encoder heads78xand80x, Y encoder heads78yand80yand Z sensor heads78zand80z) that are fixed to Y slider76. The pair of head units72are similarly configured except that they are configured laterally symmetric on the page surface inFIGS. 1 and 4. Further, the plurality of scale plates46fixed on each of the pair of X frames42xare also configured laterally symmetric inFIGS. 1 and 4.

Y linear actuator74is fixed to the lower surface of upper mount section18athat apparatus main body18has. Y linear actuator74is equipped with a linear guide that straightly guides Y slider76in the Y-axis direction, and a drive system that applies a thrust force to Y slider76. The type of the linear guide is not particularly limited, but an air bearing with a high repetitive reproducibility is suitable. Further, the type of the drive system is not particularly limited, and a linear motor, a belt (or wire) drive device or the like can be used.

Y linear actuator74is controlled by main controller50(seeFIG. 6). The stroke amount of Y slider76in the Y-axis direction by Y linear actuator74is set equivalent to the stroke amount of substrate P (substrate carrier40) in the Y-axis direction.

As illustrated inFIG. 5, head unit72is equipped with a pair of X encoder heads78x(hereinafter, referred to as “X heads78x”), a pair of Y encoder heads78y(hereinafter, referred to as “Y heads78y”) and a pair of Z sensor heads78z(hereinafter, referred to as “Z heads78z”). The pair of X heads78x, the pair of Y heads78yand the pair of Z heads78zare each disposed at a predetermined spacing in the X-axis direction.

X heads78xand Y heads78yare encoder heads of a so-called diffraction interference method as disclosed in, for example, U.S. Patent Application Publication No. 2008/0094592, and irradiate the respective corresponding scales (X scale48xand Y scale48y) with measurement beams downwardly (in the −Z direction), and receive beams (returned beams) from the respective scales, thereby supplying displacement amount information of substrate carrier40to main controller50(seeFIG. 6).

That is, in substrate position measurement system70(seeFIG. 6), for example, four X heads78xin total that the pair of heads units72have and X scales48xthat face these X heads78xconfigure, for example, four X linear encoder systems for obtaining position information of substrate carrier40in the X-axis direction. Similarly, for example, four Y heads78yin total that the pair of heads units72have and Y scales48ythat face these Y heads78yconfigure, for example, four Y linear encoder systems for obtaining position information of substrate carrier40in the Y-axis direction.

Here, the spacing between the pair of X heads78xand the spacing between the pair of Y heads78yin the X-axis direction that each of the pair of head units72has is set wider than the spacing between scale plates46adjacent to each other. Accordingly, in the X encoder systems and the Y encoder systems, at least one of the pair of X heads78xconstantly faces X scale48xand also at least one of the pair of Y heads78yconstantly faces Y scale48y, irrespective of the position of substrate carrier40in the X-axis direction.

Specifically, main controller50(FIG. 6) obtains X-position information of substrate carrier40on the basis of the average value of the outputs of the pair of X heads78xin a state where the pair X heads78xboth face X scale48x. Further, main controller50obtains the X-position information of substrate carrier40on the basis of only the output of one X head78xof the pair of X heads78xin a state where only the one X head78xfaces X scale48x. Consequently, the X encoder systems can supply the position information of substrate carrier40to main controller50without interruption. The same can be said for the Y encoder systems.

Further, as the pair of Z sensor heads78zfor obtaining position information of substrate carrier40(i.e. substrate P. SeeFIG. 3) in the Z-tilt directions, for example, laser displacement meters are used. Here, the plurality of scale plates46fixed on X frame42xcorresponding to head unit72on the −Y side are disposed in a +Y side area on the upper surface of the X frame42x(seeFIG. 1). Accordingly, in a −Y side area on the upper surface of X frame42x, a band-shaped area extending in the X-axis direction, where scale plates46are not attached, is formed.

Then, the band-shaped area described above on the upper surface of X frame42xis made to be a reflection surface by, for example, mirror polishing. Each of the pair of Z heads78zirradiates the reflection surface described above with a measurement beam (downwardly) and receives the reflected beam from the reflection surface, thereby obtaining displacement amount information in the Z-axis direction of substrate carrier40at the irradiation point of the measurement beam and supplying the displacement amount information to main controller50(seeFIG. 6). Main controller50(seeFIG. 6) obtains position information of substrate carrier40in the Z-tilt directions on the basis of the outputs of the pair of Z heads78zthat the pair of head units72each have, i.e., for example, a total of four Z-heads78z. Note that the type of Z head78zis not particularly limited, as far as Z head78zcan measure the displacement of substrate carrier40(for more detail, X frame42x) in the Z-axis direction with apparatus main body18(seeFIG. 1) serving as a reference, with a desired accuracy (resolution) and in a noncontact manner.

Here, since substrate carrier40of the present embodiment can be moved with a predetermined long stroke also in the Y-axis direction as is described above, main controller50(seeFIG. 6) drives Y slider76(seeFIG. 4) of each of the pair of head units72in the Y-axis direction, via Y linear actuator74(seeFIG. 4), to follow substrate carrier40(seeFIG. 7), depending on the position of substrate carrier40in the Y-axis direction, so that respective facing states between X heads78xand Y heads78yand scales48xand48yrespectively corresponding thereto are maintained. Main controller50comprehensively obtains position information of substrate carrier40within the horizontal plane, by using together the displacement amount (the position information) of Y sliders76(i.e. each of heads78xand78y) and the output from each of heads78xand78y.

The position (displacement amount) information of Y sliders76(seeFIG. 4) within the horizontal plane is obtained by encoder systems with the measurement accuracy equivalent to that of the encoder systems using X heads78xand Y heads78ydescribed above. As can be seen fromFIGS. 4 and 5, Y slider76has a pair of X encoder heads80x(hereinafter, referred to as “X heads80x”) and a pair of Y encoder heads80y(hereinafter, referred to as “Y heads80y”). The pair of X heads80xand the pair of Y heads80yare each disposed at predetermined spacing in the Y-axis direction.

Main controller50(seeFIG. 6) obtains position information of Y sliders76within the horizontal plane using a plurality of scale plates82fixed to the lower surface of upper mount section18aof apparatus main body18(seeFIG. 1for each of them). Scale plate82is made up of a member with a band-like shape in planar view extending in the Y-axis direction. In the present embodiment, for example, two scale plates82are disposed at a predetermined spacing (spaced apart from each other) in the Y-axis direction, above each of the pair of head units72.

As illustrated inFIG. 5, in a +X side area on the lower surface of scale plate82, an X scale84xis formed facing the pair of X heads80xdescribed above, and in a −X side area on the lower surface of scale plate82, a Y scale84yis formed facing the pair of Y heads80ydescribed above. X scale84xand Y scale84yare light-reflection-type diffraction gratings having configurations substantially similar to those of X scale48xand Y scale48yformed on scale plate46described above. Further, X head80xand Y head80yare encoder heads of a diffraction interference method having configurations similar to those of X head78xand Y head78y(the downward heads) described above.

The pair of X heads80xand the pair of Y heads80yirradiate the respective corresponding scales (X scale84xand Y scale84y) with measurement beams upwardly (in the +Z direction), and receive the beams from the respective scales, thereby supplying displacement amount information of Y slider76(seeFIG. 4) within the horizontal plane to main controller50(seeFIG. 6). The spacing in the Y-axis direction between the pair of X heads80xand the spacing in the Y-axis direction between the pair of Y heads80yare each set wider than the spacing between scale plates82adjacent to each other. Accordingly, at least one of the pair of X heads80xconstantly faces X scale84xand also at least one of the pair of Y heads80yconstantly faces Y scale84y, irrespective of the position of Y slider76in the Y-axis direction. Consequently, the position information of Y slider76can be supplied to main controller50(seeFIG. 6) without interruption.

Here, as illustrated inFIG. 4, in head unit72, since Y slider76is configured to be straightly guided in the Y-axis direction by the linear guide device, there is a possibility that a plurality of measurement heads (X heads78xand80x, Y heads78yand80y, and Z heads78zand80z) fixed to Y slider76are inclined. Therefore, main controller50(seeFIG. 6) obtains information on inclination (tilt) amount of Y slider76(including information on displacement amount in the optical axis direction) using, for example, four Z sensor heads80z(hereinafter, referred to as “Z heads80z”) that are attached to Y slider76, and also corrects the output of each of the measurement heads (X heads78xand80x, Y heads78yand80y, and Z heads78z) on the basis of the outputs of, for example, the four Z sensor heads80zin order to cancel out the inclination of Y slider76(the shift of the optical axes of the measurement beams). Note that in the present embodiment, for example, the four Z sensor heads80z(the upward heads) are disposed at four locations that do not lie on the same straight line, but this is not intended to be limiting, and may be disposed at three locations that do not lie on the same straight line.

In the present embodiment, as sensor heads80z(the upward sensors), laser displacement meters similar to sensor heads78zare used, as an example, and sensor heads80zobtain information on the inclination amount of Y slider76using a target (not illustrated) (a reflection surface extending in the Y-axis direction) that is fixed to the lower surface of upper mount section18a(seeFIGS. 9 and 11) (i.e., with upper mount section18aserving as a reference). Note that the type of sensor heads80zis not particularly limited as far as the sensor heads can obtain the information on the inclination amount of Y slider76with a desired accuracy. Further, in the present embodiment, for example, two scale plates82are disposed spaced apart in the Y-axis direction, and therefore the target that is different from scale plates82is used. However, in the case of using one longer scale plate than scale plate82of the present embodiment, the grating surface of the longer scale plate may be used as the target (the reflection surface).

InFIG. 6, a block diagram is illustrated that shows the input/output relationship of main controller50that centrally configures the control system of liquid crystal exposure apparatus10(seeFIG. 1) and performs the overall control of the respective constituents. Main controller50includes a workstation (or a microcomputer) and the like, and performs the overall control of the respective constituents of liquid crystal exposure apparatus10.

In liquid crystal exposure apparatus10(seeFIG. 1) configured as described above, under the control of main controller50(seeFIG. 6), mask M is loaded onto mask stage14by a mask loader (not illustrated) and also substrate P is loaded onto substrate stage device20(substrate carrier40and noncontact holder32) by a substrate loader (not illustrated). After that, main controller50implements alignment measurement using an alignment detection system (not illustrated), and focus mapping using an autofocus sensor (not illustrated) (a surface position measurement system of substrate P), and after the alignment measurement and the focus mapping are finished, the exposure operations of a step-and-scan method are sequentially performed with respect to a plurality of shot areas set on substrate P. Note that, although the description has been made that the focus mapping for determining the Z-direction position of substrate P is performed beforehand in liquid crystal exposure apparatus10, it is also possible that the focus mapping is not performed beforehand but is performed at any time immediately before scanning exposure is performed, while performing scanning exposure operations.

Next, an example of operations of substrate stage device20at the time of exposure operations will be described usingFIGS. 8ato 10b. Note that although in the description below, the case when four shot areas are set on one substrate P (the so-called case of preparing four areas) will be described, the number and the arrangement of the shot areas set on one substrate P can be changed as needed. Further, in the present embodiment, as an example, the description will be made assuming that the exposure processing is performed from a first shot area S1set on the −Y side and on the +X side of substrate P. Further, in order to avoid the intricacy of the drawings, a part of elements that substrate stage device20has is omitted inFIGS. 8ato10b.

FIGS. 8aand 8bshow a plan view and a front view, respectively, of substrate stage device20in a state where operations such as an alignment operation have been completed and preparation of the exposure operation with respect to the first shot area S1is finished. In substrate stage device20, as illustrated inFIG. 8a, the positioning of substrate P is performed on the basis of the output of substrate position measurement system70(seeFIG. 6) so that the +X side end of the first shot area S1is slightly on the further −X side than exposure area IA formed on substrate P by illumination light IL from projection optical system16(seeFIG. 8bfor each of them) being irradiated (however, in the state illustrated inFIG. 8a, illumination light IL has not yet been irradiated on substrate P).

Further, since the center of exposure area IA and the center of X guide bar28(i.e. noncontact holder32) substantially coincide with each other in the Y-axis direction, the +Y side end vicinity part of substrate P held by substrate carrier40protrudes from noncontact holder32. The protruding portion of substrate P is supported from below by auxiliary table34disposed on the +Y side of noncontact holder32. At this time, although the flatness correction by noncontact holder32is not performed with respect to the +Y side end vicinity part of substrate P, the exposure accuracy is not affected because the flatness corrected state is maintained for an area including the first shot area S1serving as an exposure target.

Subsequently, from the state illustrated inFIGS. 8aand 8b, substrate carrier40and noncontact holder32are integrally (synchronously) driven (accelerated, driven at the constant speed, and decelerated) in the +X direction on X guide bar28(see a black arrow inFIG. 9a), synchronously with mask M (seeFIG. 1), on the basis of the output of substrate position measurement system70(seeFIG. 6), as illustrated inFIGS. 9aand 9b. While substrate carrier40and noncontact holder32are driven at the constant speed in the X-axis direction, substrate P is irradiated with illumination light IL that has passed through mask M (seeFIG. 1) and projection optical system16(seeFIG. 9bfor each of illumination light IL and projection optical system16), and thereby a mask pattern that mask M has is transferred onto the shot area S1. At this time, substrate carrier40is finely driven as needed relative to noncontact holder32in the directions of three degrees of freedom within the horizontal plane, in accordance with the result of the alignment measurement described above, and noncontact holder32is finely driven as needed in the Z-tilt directions in accordance with the result of the focus mapping described above.

Here, in substrate position measurement system70(seeFIG. 6), when substrate carrier40and noncontact holder32are driven in the X-axis direction (the +X direction inFIG. 9a), Y sliders76that the pair of head units72respectively have are in a static state.

When the transfer of the mask pattern on the first shot area S1on substrate P has been completed, in substrate stage device20, as illustrated inFIGS. 10aand 10b, for the exposure operation with respect to a second shot area S2set on the +Y side of the first shot area S1, substrate carrier40is driven (Y-step driven) by a predetermined distance in the −Y direction (a distance that is substantially a half of the width direction size of substrate P) (see outlined arrows inFIG. 10a), on the basis of the output of substrate position measurement system70(seeFIG. 6). By the foregoing Y-step operation of substrate carrier40, the −Y side end vicinity part of substrate P held by substrate carrier40is supported from below by auxiliary table34disposed on the −Y side of noncontact holder32.

Further, when driving substrate carrier40described above in the −Y direction, main controller50(seeFIG. 6) drives Y sliders76that the pair of head units72respectively have (seeFIG. 4for each of them) in the −Y direction (see black arrows inFIG. 10a) to be in synchronization with substrate carrier40in the Y-axis direction. That is, as illustrated inFIG. 7, in the case when substrate carrier40is moved with a predetermined stroke in the −Y direction, the pair of Y sliders76are moved synchronously with substrate carrier40in the −Y direction. In this case, in the present specification, “being moved synchronously” means that substrate carrier40and Y sliders76are moved in a state of substantially maintaining the relative positional relationship, and is not limited to the case when substrate carrier40and Y sliders76are moved in a state where their positions (the movement directions and the velocities) exactly coincide.

Then, although not illustrated, substrate carrier40and noncontact holder32are driven in the −X direction, synchronously with mask M (seeFIG. 1), and thereby the scanning exposure with respect to the second shot area S2is performed. Further, the Y-step operation of substrate carrier40and the constant speed movement of substrate carrier40and noncontact holder32in the X-axis direction in synchronization with mask M are repeated as needed, and thereby the scanning exposure operations with respect to all the shot areas set on substrate P are sequentially performed.

According to substrate stage device20described so far that liquid crystal exposure apparatus10related to the present first embodiment has, since substrate position measurement system70for obtaining position information of substrate P within the XY plane includes the encoder systems, the influence by air fluctuation can be reduced, compared with, for example, conventional interferometer systems. Consequently, the positioning accuracy of substrate P is improved. Further, since the influence by air fluctuation is small, a partial air-conditioning facility that is essential in the case of using the conventional interferometer systems can be omitted, which allows the cost to be reduced.

Moreover, in the case of using interferometer systems, a large and heavy bar mirror is required to be equipped in substrate stage device20. However, since such a bar mirror is unnecessary in the encoder systems related to the present embodiment, a system including substrate carrier40is downsized and lightened and also the better weight balance is obtained, and accordingly the position controllability of substrate P is improved. Further, the points to be adjusted can be decreased, compared with the case of using the interferometer systems, which leads to the cost reduction of substrate stage device20and further leads to the improved maintainability. Furthermore, the adjustment at the time of assembly is also facilitated.

Further, in substrate position measurement system70(the encoder systems) related to the present embodiment, since such a configuration is employed that the Y-position information of substrate P is obtained by driving the respective Y sliders76of the pair of head units72synchronously with substrate P (causing Y sliders to follow substrate P) in the Y-axis direction, a scale extending in the Y-axis direction needs not be disposed on the substrate stage device20side (or a plurality of heads need not be arrayed in the Y-axis direction on the apparatus main body18side). Consequently, the configuration of substrate position measurement system70can be simplified, which allows the cost to be reduced.

Further, in substrate position measurement system70(the encoder systems) related to the present embodiment, since such a configuration is employed that the position information of substrate carrier40within the XY plane is obtained while switching the outputs of the pair of encoder heads (X heads78xand Y heads78y) adjacent to each other depending on the X-position of substrate carrier40, the position information of substrate carrier40can be obtained without interruption even if the plurality of scale plates46are disposed at a predetermined spacing (spaced apart from each other) in the X-axis direction. Consequently, a scale plate with a length equivalent to the stroke amount of substrate carrier40needs not be prepared, which allows the cost to be reduced and is especially suitable for liquid crystal exposure apparatus10using substrate P with a large size as in the present embodiment.

Further, in substrate stage device20, when the high accuracy positioning of substrate P within the XY plane is performed, substrate carrier40with a frame-like shape that holds only the outer periphery edge of substrate P is driven in the directions of three degrees of freedom within the horizontal plane. Therefore, an object to be driven (substrate carrier40in the present embodiment) is lightweight, compared with, for example, the case of performing the high accuracy positioning of substrate P by driving a substrate holder that adsorbs and holds the entire lower surface of substrate P in the directions of three degrees of freedom within the horizontal plane, and thus the position controllability is improved. Further, the actuators for driving (Y voice coil motors64and X voice coil motors66in the present embodiment) can be downsized.

Second Embodiment

Next, a second embodiment will be described usingFIG. 11. A liquid crystal exposure apparatus related to the present second embodiment obtains position information of substrate P within the horizontal plane using encoder systems, similarly to the first embodiment described above, but the second embodiment is different from the first embodiment described above in that head units for the encoder systems (a horizontal-in-plane position measurement system) and head units for Z-tilt position measurement system are independent from each other. Hereinafter, the differences from the first embodiment described above will be described, and elements that have the same configurations and functions as those in the first embodiment described above will be provided with the same reference signs as those in the first embodiment described above, and the description thereof will be omitted.

A substrate position measurement system70A related to the present second embodiment has one head unit72A and two head units72B on each of one side and the other side of projection optical system16(seeFIG. 1) in the Y-axis direction (only the one side is illustrated inFIG. 11). The position in the X-axis direction of head unit72A substantially coincides with that of projection optical system16. The two head units72B are disposed on one side and the other side of head unit72A in the X-axis direction.

Head unit72A is a head unit that is configured by removing Z heads78zand80zfrom head unit72(seeFIG. 5) related to the first embodiment described above. That is, head unit72A obtains position information of substrate carrier40within the XY plane, by a pair of X heads78xand a pair of Y heads78y, using a plurality of scale plates46attached to substrate carrier40. The points that the pair of X heads78xand the pair of Y heads78yare moved synchronously with substrate carrier40in the Y-axis direction, and the position information of the pair of X heads78xand the pair of Y heads78yis obtained by the pair of X heads80xand the pair of Y heads80yby using scale plates82are the same as the first embodiment described above, and therefore the description thereof will be omitted.

Head unit72B is a head unit that is configured by removing X heads78xand80xand Y heads78yand80yfrom head unit72(seeFIG. 5) related to the first embodiment described above. That is, head unit72B obtains position information of substrate carrier40in the Z-tilt directions by the pair of Z heads78zusing the upper surface (the reflection surface) of X frame42xof substrate carrier40. The points that the pair of Z heads78zare moved synchronously with substrate carrier40in the Y-axis direction, and that the attitude change of substrate carrier40is obtained by, for example, four Z heads80z, using a target82B fixed to apparatus main body18(seeFIG. 1) are the same as the first embodiment described above, and therefore the description thereof will be omitted.

According to the present second embodiment, since head unit72A of a position measurement system for substrate P within the horizontal plane and head units72B of a position measurement system for substrate P in the Z-tilt directions are independent from each other, the configurations of the head units are simpler and the arrangement of each of the measurement heads is easier, compared to the first embodiment described above.

Third Embodiment

Next, a third embodiment will be described usingFIGS. 12aand 12b. In the configuration of a liquid crystal exposure apparatus related to the present third embodiment, the configuration of a substrate stage device120for performing the high accuracy positioning of substrate P with respect to projection optical system16(seeFIG. 1) is different from that in the first embodiment described above. The configuration of a measurement system for obtaining position information of substrate P in the directions of six degrees of freedom is the same as the first embodiment described above. Hereinafter, in the present third embodiment, only the differences from the first embodiment described above will be described, and elements that have the same configurations and functions as those in the first embodiment described above will be provided with the same reference signs as those in the first embodiment described above, and the description thereof will be omitted.

Substrate carrier40with a frame-like shape (a picture-frame-like shape) that holds substrate P is relatively movable with a predetermined stroke independently from noncontact holder32in the non-scanning direction (the Y-axis direction) in the first embodiment described above (see the drawings such asFIG. 1), whereas in substrate stage device120in the present third embodiment as illustrated inFIGS. 12aand 12b, a substrate carrier140is moved with a predetermined stroke integrally with noncontact holder32in each of the scanning direction (the X-axis direction) and the non-scanning direction, which is different from the first embodiment described above. The point that substrate carrier140is relatively movable with a fine stroke with respect to noncontact holder32in the directions of three degrees of freedom within the horizontal plane is similar to substrate stage device20of the first embodiment described above.

More specifically, in the present third embodiment, a coarse movement stage124is configured movable with a predetermined long stroke in the X-axis direction and the Y-axis direction. Although the configuration for moving coarse movement stage124with a long stroke in the Y-axis direction is not particularly limited, a gantry type XY stage device known to public that is disclosed in, for example, U.S. Patent Application Publication No. 2012/0057140 and the like can be used. Further, weight cancelling device26is coupled to coarse movement stage124to be moved with a predetermined long stroke integrally with coarse movement stage124in the X-axis direction and the Y-axis direction. Further, X guide bar28(see the drawings such asFIG. 1) is also movable with a predetermined long stroke in the Y-axis direction. Although a configuration for moving X guide bar28with a long stroke in the Y-axis direction is not particularly limited, such a configuration should be mechanically coupled to, for example, a Y stage of the XY stage device described above. The point that coarse movement stage124and substrate table30are mechanically coupled (however, in a state of being finely movable in the Z-tilt directions) via a plurality of coupling devices30b(flexure devices) is the same as the first embodiment described above. Accordingly, substrate table30and noncontact holder32are moved with a predetermined long stroke integrally with coarse movement stage124in the X-axis direction and the Y-axis direction.

Substrate carrier140has a main body section142formed into a rectangular frame-like shape in planar view, and an adsorption section144fixed to the upper surface of main body section142. Adsorption section144is also formed into a rectangular frame-like shape in planar view, similarly to main body section142. Substrate P is held by, for example, vacuum adsorption by adsorption section144. Noncontact holder32described above is inserted into an opening that adsorption section144has, in a state where a predetermined gap is formed between noncontact holder32and the inner wall surface of adsorption section144. The point that noncontact holder32causes the load (the preload) to act on substrate P, thereby performing flatness correction in a noncontact manner is the same as the first embodiment described above.

Further, from the lower surface of substrate table30, a plurality (e.g. four in the present embodiment) of guide plates148radially extend along the horizontal plane. Substrate carrier140has a plurality of pads146including air bearings, corresponding to the plurality of guide plates148, and substrate carrier140is placed in a noncontact state on guide plates148by a static pressure of the pressurized gas blown out from the air bearings to the upper surfaces of guide plates148. In the case when substrate table30is finely driven in the Z-tilt directions, the plurality of guide plates148are also moved in the Z-tilt directions (the attitude is changed) integrally with substrate table30, and therefore, when the attitude of substrate table30is changed, the attitudes of substrate table30, noncontact holder32and substrate carrier140(i.e. substrate P) are integrally changed.

Further, substrate carrier140is finely driven with respect to substrate table30in the directions of three degrees of freedom within the horizontal plane via a plurality of linear motors152(X voice coil motors and Y voice coil motors) including movers that substrate carrier140has and stators that substrate table30has. Further, when substrate table30is moved with a long stroke along the XY plane, the thrust forces is applied to substrate carrier140by the plurality of linear motors152described above, so that substrate table30and substrate carrier140are integrally moved with a long stroke along the XY plane.

A plurality of scale plates46are fixed to each of the +Y side end vicinity part and the −Y side end vicinity part of the upper surface of substrate carrier140, similarly to the first embodiment described above. Since the way to obtain position information of substrate carrier140(i.e. substrate P) in the directions of six degrees of freedom using scale plates46and the upper surface (the reflection surface) of substrate carrier140is the same as that of the first embodiment described above, the description thereof will be omitted.

Note that the configurations described in each of the first to third embodiments described above can be changed as needed. For example, in each of the embodiments described above, although a plurality of scale plates46are arrayed at a predetermined spacing in the X-axis direction on substrate carrier40or140, a long scale plate whose length in the X-axis direction is about the same as the length of substrate P may be used. In this case, each of the pair of head units72only has to be provided with one each of X head78xand Y head78y. In the case when a plurality of scale plates46are provided, the respective lengths of the plurality of scale plates46may be different from each other. For example, the length of a scale plate extending in the X-axis direction is set longer than the length of a shot area in the X-axis direction, and thereby the position control of substrate P by head unit72that is located across the different scale plates46can be avoided at the time of scanning exposure operations. Further (for example, in the case of preparing four areas and the case of preparing six areas), a scale disposed on one side of projection optical system16and a scale disposed on the other side may have the respective lengths different from each other. Further, in the case when a plurality of scale groups (scale rows), in each of which a plurality of scale plates disposed in the Y-axis direction are arranged in line via a gap of a predetermined spacing, are disposed at different positions spaced from each other in the X-axis direction (e.g., the position on one side (the +X side) and the position on the other side (the X side) with respect to projection optical system16), the positions of the gaps of the predetermined spacing described above may be disposed not to overlap in the Y-axis direction among the plurality of scale rows. By disposing the plurality of scale rows in this manner, the heads placed corresponding to the respective scale rows can be prevented from being simultaneously located outside the measurement range (in other words, both the heads can be prevented from simultaneously facing the gaps).

Further, in scale groups (scale rows) on substrate carrier40, in each of which a plurality of scales are arranged in line via a gap of a predetermined spacing in the X-axis direction, the scales with the same length are arranged in line in the embodiments described above, but the scales with lengths different from each other may be arranged in line. For example, in a scale row on substrate carrier40, the length in the X-axis direction of scales disposed in the central part may be set physically longer than the length in the X-axis direction of scales disposed near both ends in the X-axis direction (scales disposed at the respective ends in a scale row).

Further, in scale groups (scale rows) on substrate carrier40, in each of which a plurality of scales are arranged in line via a gap of a predetermined spacing in the X-axis direction, the length of one scale (a pattern for X-axis measurement) in the X-axis direction may be set to a length with which the measurement corresponding to only the length of one shot area can be continuously performed (a length along which a device pattern is irradiated and formed on a substrate when scanning exposure is performed while moving the substrate on a substrate holder in the X-axis direction). By setting the length of one scale in the X-axis direction in this manner, the transfer control of heads with respect to a plurality of scales do not have to be performed during the scanning exposure of one shot area, and therefore the position measurement (the position control) of substrate P (the substrate holder) during the scanning exposure can be performed easily.

Further, although the position information of each of substrate P and Y sliders76within the XY plane is obtained by X encoder heads78xand80xand Y encoder heads78yand80y, Z-tilt displacement amount information of each of substrate P and Y sliders76may also be obtained together with the position information of each of substrate P and Y sliders76within the XY plane, by using, for example, a two-dimensional encoder head (an XZ encoder head or a YZ encoder head) that is capable of measuring displacement amount information in the Z-axis direction. In this case, sensor heads78zand80zfor obtaining the Z-tilt position information of substrate P can be omitted. Note that, in this case, since two downward Z heads need to constantly face scale plate46in order to obtain the Z-tilt position information of substrate P, it is preferable that scale plate46is configured of one long scale plate with a length that is about the same as the length of X frame42x, or for example, three or more of the two-dimensional encoder heads described above are disposed at a predetermined spacing in the X-axis direction.

Further, although in the encoder systems in the each of the embodiments described above, such a configuration is employed that substrate carrier40or140has scale plates46(diffraction gratings) and head units72have measurement heads, this is not intended to be limiting, and substrate carrier40or140may have measurement heads and scale plates that are moved synchronously with the measurement heads may be attached to apparatus main body18(the arrangement reversed to that in each of the embodiments described above may be employed).

Further, although in each of the embodiments described above, a plurality of scale plates46are disposed at a predetermined spacing in the X-axis direction, this is not intended to be limiting, and for example, one long scale plate formed with a length about the same as the length of substrate carrier40in the X-axis direction may be used. In this case, since the facing state between the scale plate and the heads is constantly maintained, each head unit72only has to have one each of X head78xand Y head78y. The same can be said for scale plate82. Further, although in the first embodiment described above, scale plates46are attached to the substantially entire area of the upper surface of X frame42x, the range in which scale plates46are attached can be changed as needed, depending on the movement range of substrate carrier40in the X-axis direction. That is, the attachment range of scale plates46may be shorter as far as it is possible for the plurality of heads to face scale plate46located closest to the +X side and scale plate46located closest to the −X side within the movement range of substrate carrier40. Further, depending on the circumstances, a plurality of scale plates (or one long scale plate) may be provided in a range longer than the length of X frame42xin the X-axis direction, and in this case, scale plate(s)46may be attached to another member longer than X frame42xin the X-axis direction. Further, although in each of the embodiments described above, two-dimensional measurement is performed by combining one-dimensional encoder systems configured of one-dimensional scales and one-dimensional heads, this is not intended to be limiting, and a two-dimensional encoder system that is configured of two-dimensional scales (XY scales) and two-dimensional heads (XY heads) may be used.

Further, although in each of the embodiments described above, the position information of substrate carrier40or140and the position information of Y sliders76are each obtained by the encoder systems, this is not intended to be limiting, and position information of Y sliders76may be obtained by another measurement system such as, for example, an optical interferometer system.

Further, substrate stage device20of the first embodiment described above is configured so that noncontact holder32and substrate carrier40are integrally movable in the X-axis (scanning) direction and substrate carrier40is movable relative to noncontact holder32in the Y-axis (non-scanning) direction. However, inversely to this configuration, substrate stage device20may be configured so that noncontact holder32and substrate carrier40are integrally movable in the Y-axis direction and substrate carrier40is movable relative to noncontact holder32in the X-axis direction. In this case, since only substrate carrier40has to be moved with a long stroke in the scanning direction at the time of scanning exposure operations and thus an object to be driven is lightweight, the position controllability is improved. Further, the actuators for driving can be downsized.

Further, although in each of the embodiments described above, substrate carrier40or the like is formed into a rectangular frame-like shape by, for example, four frame members along the outer periphery edges (four sides) of substrate P (in the first embodiment, a pair of X frames42xand a pair of Y frames42y), this is not intended to be limiting as far as the holding by adsorption of substrate P can be reliably performed. And, substrate carrier40or the like may be configured of frame members, for example, along a part of the outer periphery edges of substrate P. Specifically, the substrate carrier may be formed into a U-like shape in planar view by, for example, three frame members along three sides of substrate P, or may be formed into an L-like shape in planar view by, for example, two frame members along two adjacent sides of substrate P. Further, the substrate carrier may be formed by, for example, only one frame member along one side of substrate P. Further, the substrate carrier may be configured by a plurality of members which hold portions different from each other of substrate P and whose positions are controlled independently from each other.

Further, although in each of the embodiments described above, noncontact holder32supports substrate P in a noncontact manner, this is not intended to be limiting as far as the relative movement of substrate P and noncontact holder32in directions parallel to the horizontal plane is not blocked, and substrate P may be supported in a contact state via a rolling element such as, for example, a ball.

Further, a light source used in illumination system12and the wavelength of illumination light IL irradiated from the light source are not particularly limited, and for example, may be ultraviolet light such as an ArF excimer laser beam (with a wavelength of 193 nm) or a KrF excimer laser beam (with a wavelength of 248 nm), or vacuum ultraviolet light such as an F2laser beam (with a wavelength of 157 nm).

Further, although in each of the embodiments described above, an unmagnification system is used as projection optical system16, the projection optical system is not limited thereto, and a reduction system or a magnifying system may be used.

Further, the use of the exposure apparatus is not limited to the exposure apparatus for liquid crystal display devices that transfers a liquid crystal display device pattern onto a square-shaped glass plate, but can be widely applied also to, for example, an exposure apparatus for manufacturing organic EL (Electro-Luminescence) panels, an exposure apparatus for manufacturing semiconductor devices, and an exposure apparatus for manufacturing thin-film magnetic heads, micromachines, DNA chips or the like. Further, each of the embodiments described above can also be applied to an exposure apparatus that transfers a circuit pattern onto a glass substrate or a silicon wafer or the like, not only when producing microdevices such as semiconductor devices, but also when producing a mask or a reticle used in an exposure apparatus such as an optical exposure apparatus, an EUV exposure apparatus, an X-ray exposure apparatus, or an electron beam exposure apparatus.

Further, an object serving as an exposure target is not limited to a glass plate, but may be other objects such as, for example, a wafer, a ceramic substrate, a film member, or a mask blank. Further, in the case when an object to be exposed is a substrate for flat-panel display, the thickness of the substrate is not particularly limited, and for example, a film-like member (a sheet-like member with flexibility) is also included. Note that the exposure apparatus of the present embodiments is especially effective in the case when a substrate having a side or a diagonal line with a length of 500 mm or greater is an object to be exposed. Further, in the case when a substrate serving as an exposure target is like a sheet with flexibility, the sheet may be formed into a roll state.

Electronic devices such as liquid crystal display devices (or semiconductor devices) are manufactured through the steps such as: a step in which the function/performance design of a device is performed; a step in which a mask (or a reticle) based on the design step is manufactured; a step in which a glass substrate (or a wafer) is manufactured; a lithography step in which a pattern of the mask (the reticle) is transferred onto the glass substrate with the exposure apparatus in each of the embodiments described above and the exposure method thereof; a development step in which the glass substrate that has been exposed is developed; an etching step in which an exposed member of the other section than a section where resist remains is removed by etching; a resist removal step in which the resist that is no longer necessary when etching is completed is removed; a device assembly step; and an inspection step. In this case, in the lithography step, the exposure method described previously is implemented using the exposure apparatus in the embodiments described above and a device pattern is formed on the glass substrate, and therefore, the devices with a high integration degree can be manufactured with high productivity.

Incidentally, the disclosures of all the U.S. Patent Application Publications and the U.S. Patents related to exposure apparatuses and the like that are cited in the embodiments described above are each incorporated herein by reference.

INDUSTRIAL APPLICABILITY

As is described so far, the movable body apparatus and the movement method of objects of the present invention are suitable for moving objects. Further, the exposure apparatus of the present invention is suitable for exposing objects. Further, the manufacturing method of flat-panel displays of the present invention is suitable for manufacturing of flat-panel displays. Further, the device manufacturing method of the present invention is suitable for manufacturing of microdevices.

REFERENCE SIGNS LIST