Scaling method for a digital photolithography system

[0002] This patent is a continuation-in-part of U.S. patent Ser. No. 09/712,730 filed Nov. 14, 2000, now U.S. Pat. No. 6,493,867 which is hereby incorporated by reference.

[0003] The present invention relates generally to lithographic exposure equipment, and more particularly, to a photolithography system and method, such as can be used in the manufacture of semiconductor integrated circuit devices.

[0004] In conventional analog photolithography systems, the photographic equipment requires a mask for printing an image onto a subject. The subject may include, for example, a photo resist coated semiconductor substrate for manufacture of integrated circuits, metal substrate for etched lead frame manufacture, conductive plate for printed circuit board manufacture, or the like. A patterned mask or photomask may include, for example, a plurality of lines or structures. During a photolithographic exposure, the subject must be aligned to the mask very accurately using some form of mechanical control and sophisticated alignment mechanism.

[0005] U.S. Pat. No. 5,691,541, which is hereby incorporated by reference, describes a digital, reticle-free photolithography system. The digital system employs a pulsed or strobed excimer laser to reflect light off a pixel panel (e.g., a programmable digital mirror device, or “DMD”) for projecting an image (e.g., a line or pattern) onto a subject (e.g., a wafer, printed circuit board, textile, flexible member). The subject is mounted on a stage that is moves during the sequence of pulses.

[0006] The above-described digital photolithography system projects a pixel-mask pattern onto a subject such as a wafer, printed circuit board, or other medium. The component image consists of a plurality of pixel elements, corresponding to a pixel pattern provided to the pixel panel. As a result, light can be projected onto or through the pixel panel to expose the plurality of pixel elements on the subject, and the pixel elements can be moved and altered, according to the pixel-mask pattern, to create contiguous images on the subject.

[0007] Certain improvements are desired for digital photolithograph systems, such as the ones described above. For one, it is desirable to accommodate a desired change in the scale of the images being exposed. For example, if the subject were a textile, the image may need to expand and/or contract to accommodate the flexibility in the textile. In another example, it may be desirable to scale the image for other reasons.

[0008] A technical advance is provided by a novel method and system for scaling a pixel element on a subject. In one embodiment, the subject is positioned in a first plane and the method comprises providing a pixel panel to generate the pixel element, where the pixel panel is positioned in a second plane substantially parallel to the first plane. A first scan rate is determined, and an original focal point of the pixel element on the subject is determined. A scaled focal point is calculated for the pixel element on the subject, where the scaled focal point includes a first coordinate in a first dimension and a second coordinate in a second dimension. The pixel panel is rotated relative to the subject to position the pixel element at the first coordinate in rotated relative to the subject to position the pixel element at the first coordinate in the first dimension of the scaled focal point, and the first scan rate is altered to a second scan rate to position the pixel element at the second coordinate in the second dimension of the scaled focal point.

[0009] FIG. 1 is a block diagram of an improved digital photolithography system for implementing various embodiments of the present invention.

[0010] FIGS. 2 and 3 illustrate various overlay arrangement of pixels being exposed on a subject.

[0011] FIGS. 4 and 5 illustrate the effect of overlaid pixels on the subject.

[0012] FIG. 6 illustrates a component exposure from the system of FIG. 1, compared to conventional exposures from the systems of FIGS. 1band 1a.

[0013] FIG. 7 illustrates various pixel patterns being provided to a pixel panel of the system of FIG. 1.

[0014] FIGS. 8, 9, and 10.1-10.20 provide diagrams of a subject that is positioned and scanned at an angle on a stage. The angle facilitates the overlapping exposure of a site on the subject according to one embodiment of the present invention.

[0015] FIG. 11 is a block diagram of a portion of the digital photolithography system of FIG. 1 for implementing additional embodiments of the present invention.

[0016] FIGS. 12-13 provide diagrams of a subject that is positioned and scanned at an angle on a stage and being exposed by the system of FIG. 11.

[0017] FIG. 14 illustrates a site that has been overlapping exposed 600 times.

[0018] FIG. 15 illustrates a pixel that is to be horizontally scaled by a pixel panel rotatably aligned with a subject.

[0019] FIG. 16 is a flow chart illustrating a method for scaling a pixel.

[0020] FIG. 17aillustrates a pixel that is to be horizontally scaled by rotating a pixel panel with respect to a subject.

[0021] FIG. 17billustrates an enlarged view of the area within the dashed line of FIG. 17a.

[0022] FIG. 18 illustrates a subject containing a pixel location that is inaccessible to a pixel panel as aligned with the subject.

[0023] FIG. 19 illustrates the pixel panel of FIG. 18 after being rotated to access the pixel location.

[0024] The present disclosure relates to exposure systems, such as can be used in semiconductor photolithographic processing. It is understood, however, that the following disclosure provides many different embodiments, or examples, for implementing different features of the invention. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to limit the invention from that described in the claims.

[0025] Referring now to FIG. 1, a maskless photolithography system 30 includes a light source 32, a first lens system 34, a computer aided pattern design system 36, a pixel panel 38, a panel alignment stage 39, a second lens system 40, a subject 42, and a subject stage 44. For the sake of example, the subject 42 may be a semiconductor wafer with a resist layer or coating 46 disposed thereon. The light source 32 may be an incoherent light source (e.g., a Mercury lamp) that provides a collimated beam of light 48 which is projected through the first lens system 34 and onto the pixel panel 38.

[0026] The pixel panel 38 is provided with digital data via suitable signal line(s) 50 from the computer aided pattern design system 36 to create a desired pixel pattern (the pixel-mask pattern). The pixel-mask pattern may be available and resident at the pixel panel 38 for a desired, specific duration. Light emanating from (or through) the pixel-mask pattern of the pixel panel 38 then passes through the second lens system 40 and onto the subject 42. In this manner, a pixel image is projected onto the resist coating 46 of the subject 42.

[0027] The computer aided mask design system 36 can be used for the creation of the digital data for the pixel-mask pattern. The computer aided pattern design system 36 may include computer aided design (CAD) software similar to that which is currently used for the creation of mask data for use in the manufacture of a conventional printed mask. Any modifications and/or changes required in the pixel-mask pattern can be made using the computer aided pattern design system 36. Therefore, any given pixel-mask pattern can be changed, as needed, almost instantly with the use of an appropriate instruction from the computer aided pattern design system 36. The computer aided mask design system 36 can also be used for adjusting a scale of the image or for correcting image distortion.

[0028] In the present embodiment, the pixel panel 38 is a digital light processor (DLP) or digital mirror device (DMD) such as is illustrated in U.S. Pat. No. 5,079,544 and patents referenced therein. Current DMD technology provides a 600×800 array of mirrors for a set of potential pixel elements. Each mirror can selectively direct the light 48 towards the subject 42 (the “ON” state) or away from the subject (the “OFF” state). Furthermore, each mirror can alternate between ON and OFF for specific periods of time to accommodate variations in light efficiency. For example, if the second lens system 40 has a “darker” area (e.g., a portion of the lens system is inefficient or deformed), the DMD can alternate the mirrors corresponding with the “brighter” areas of the lens, thereby equalizing the overall light energy projected through the lens. For the sake of simplicity and clarity, the pixel panel 38 will be further illustrated as one DMD. Alternate embodiments may use multiple DMDs, one or more liquid crystal displays and/or other types of digital panels.

[0029] In some embodiments, the computer aided mask design system 36 is connected to a first motor 52 for moving the stage 44, and a driver 54 for providing digital data to the pixel panel 38. In some embodiments, an additional motor 55 may be included for moving the pixel panel, as discussed below. The system 36 can thereby control the data provided to the pixel panel 38 in conjunction with the relative movement between the pixel panel 38 and the subject 42.

[0030] In some embodiments, the amount of exposure time, or exposure intensity, of light from the pixel panel 38 directly affects the resist coating 46. For example, if a single pixel from the pixel panel 38 is exposed for a maximum amount of time onto a single site of the subject 42, or for a maximum intensity, then the corresponding portion of resist coating 46 on the subject would have a maximum thickness (after non-exposed or under exposed resist has been removed). If the single pixel from the pixel panel 38 is exposed for less than the maximum amount of time, or at a reduced intensity, the corresponding portion of resist coating 46 on the subject 42 would have a moderate thickness. If the single pixel from the pixel panel 38 is not exposed, then the corresponding portion of resist coating 42 on the subject 42 would eventually be removed.

[0031] Referring now to FIGS. 2 and 3, it is desired that each pixel element exposed onto a site overlap previous pixel element exposures. FIG. 2 shows a one-direction overlay scenario where a pixel element 80.1 is overlapped by pixel element 80.2, which is overlapped by pixel element 80.3, . . . which is overlapped by pixel element 80.N, where “N” is the total number of overlapped pixel elements in a single direction. It is noted that, in the present example, pixel element 80.1 does not overlay pixel element 80.N.

[0032] FIG. 3 is a two-dimensional expansion FIG. 2. In this example, pixel element 80.1 is overlapped in another direction by pixel element 81.1, which is overlapped by pixel element 82.1, . . . which is overlapped by pixel element 8M.N, where “M” is the total number of overlapped pixel elements in a second direction. As a result, a total of M×N pixel elements can be exposed for a single site.

[0033] Referring now to FIG. 4, consider for example a site that has the potential to be exposed by (M,N)=(4,4) pixel elements. In this example, only four of the 16 possible pixel elements are actually “ON”, and therefore expose portions of the subject 42. These four pixel elements are designated: 100.1, 100.2, 100.3, 100.4. The four pixel elements 100.1-100.4 are exposed onto the photo resist 46 of the subject 42. All four pixel elements 100.1-100.4 overlap with each other at an area 102; three of the pixel elements overlap at an area 104; two of the pixel elements overlap at an area 106; and an area 108 is only exposed by one pixel element. Accordingly, area 102 will receive maximum exposure (100%); area 104 will receive 75% exposure; area 106 will receive 50% exposure; and area 108 will receive 25% exposure. It is noted that the area 102 is very small, {fraction (1/16)}th the size of any pixel element 100.1-100.4 in the present example.

[0034] Referring now to FIG. 5, the example of FIG. 4 can be expanded to (M,N)=(6,6) pixel elements, with two more overlapping pixel elements 100.5, 100.6 in the ON state. The pixel elements 100.5, 100.6 are therefore exposed onto the photo resist 46 of the subject 42 so that they overlap some of the four pixel elements 100.1-100.4. In this expanded example, the pixel elements 100.1-100.4 overlap with each other at area 102; the four pixel elements 100.2-100.5 overlap each other at an area 110; and the four pixel elements 100.3-100.6 overlap each other at an area 112. In addition, area 114 will receive 75% exposure; area 116 will receive 50% exposure; and area 118 will receive 25% exposure. As a result, a very small ridge is formed on the photo resist 46.

[0035] In one embodiment, the pixel panel 32 of the present invention may have a 600×800 array of pixel elements. The overlapping is defined by the two variables: (M, N). Considering one row of 600 pixels, the system overlaps the 600 pixels onto an overlay area 184 of:

[0036] (M,N)=20 pixels×30 pixels.  (1)

[0037] Referring also to FIG. 6, the process of FIGS. 4 and 5 can be repeated to produce a diagonal component 120 on the subject 42. Although the example of FIGS. 4 and 5 have only four potential degrees of exposure (100%, 75%, 50%, 25%), by increasing the number of overlaps (such as is illustrated in FIG. 3), it is possible to have a very fine resolution of desired exposure.

[0038] The diagonal component 120 appears as a prism-shaped structure having a triangular cross-section. If the subject 42 is a wafer, the component 120 may be a conductor (e.g., a metal line), a section of poly, or any other structure. The top most portion 120tof the component is the portion of photo resist 46 that is overlapped the most by corresponding pixel elements, and therefore received the maximum exposure.

[0039] Referring again to FIG. 1, the above-described overlays can be implemented by various systems and methods. In general, various combinations of moving and/or arranging the pixel panel 38 and/or the subject 42 can achieve the desired overlap.

[0040] In one embodiment, the maskless photolithography system 30 performs two-dimensional digital scanning by rapidly moving the image relative to the subject in two directions (in addition to the scanning motion). The panel motor 55 is attached to the pixel panel 38 to move the pixel panel in two directions, represented by an x-arrow 132 and a y-arrow 134. The panel motor 55 may be a piezo electric device (PZT) capable of making very small and precise movements.

[0041] In addition, the scanning motor 55 scans the stage 44, and hence the subject 42, in a direction 136. Alternatively, the stage 44 can be fixed and the panel motor 55 can scan the pixel panel 38 (and the lenses 40) opposite to direction 136.

[0042] Referring also to FIG. 7, corresponding to the image scanning described above, the pixel-mask pattern being projected by the pixel panel 38 changes accordingly. This correspondence can be provided, in one embodiment, by having the computer system 36 (FIG. 1) control both the scanning movement 70 and the data provided to the pixel panel 38. The illustrations of FIG. 7 and the following discussions describe how the data can be timely provided to the pixel panel.

[0043] FIG. 7 shows three intermediate patterns of pixel panel 38. Since the pattern on the pixel panel 38 and the data on the signal lines 50 change over time, the corresponding patterns on the pixel panel and data on the signal lines at a specific point in time are designated with a suffix “.1”, “.2”, or “.3”. In the first intermediate pattern, the pattern of pixel panel 38.1 is created responsive to receiving data D0 provided through the signal lines 50.1. In the present example, the pattern is created as a matrix of pixel elements in the pixel panel 38.1. After a predetermined period of time (e.g., due to exposure considerations being met), the pattern is shifted. The shifted pattern (now shown as pixel panel 38.2) includes additional data D1 provided through the signal lines 38.2. The shifting between patterns may also utilize a strobing or shuttering of the light source 32.

[0044] In the second intermediate pattern of FIG. 7, D1 represents the left-most column of pixel elements in the pattern of DMD 38.2. After another predetermined period of time, the pattern (now shown as pixel panel 38.3) is shifted again. The twice-shifted pattern includes additional data D2 provided through the signal lines 38.2. In the third intermediate pattern of FIG. 7, D2 now represents the left-most column of pixel elements in the pattern of the DMD 38.3. Thus, the pattern moves across the pixel panel 38 in a direction 138. It is noted that the pattern direction 138, as it is being provided to the pixel panel 38 from the signal lines 50, is moving opposite to the scanning direction 136. In some embodiments, the pattern may be shifted in additional directions, such as perpendicular to the scanning direction 136.

[0045] Referring now to FIG. 8, in some embodiments, the maskless photolithography system 30 performs two-dimensional digital scanning by rapidly moving the image relative to the subject 42 in one direction (in addition to the scanning motion) while the subject is positioned on the stage 44 to accommodate the other direction. The panel motor 55 moves the pixel panel 38 in one direction, represented by the y-arrow 134. The scanning motor 55 scans the stage 44, and hence the subject 42 in a direction 136. Alternatively, the stage 44 can be fixed and the panel motor 55 can scan the pixel panel 38 (and the lenses 40) opposite to direction 136.

[0046] The image from the pixel panel 38 and/or the subject 42 is aligned at an angle θ with the scan direction 136. Considering that each pixel projected onto subject 42 has a length of l and a width of w, then θ can be determined as: $\begin{array}{cc}\theta ={\tan }^{-1}\left(\frac{w-1/M}{N\times l}\right)& \left(2\right)\end{array}$

[0047] In another embodiment, the offset may go in the opposite direction, so that θ can be determined as: $\begin{array}{cc}\theta ={\tan }^{-1}\left(\frac{w+1/M}{N\times l}\right)& \left(3\right)\end{array}$

[0048] Referring to FIGS. 9 and 10.1, consider for example two sites 140.1, 142.1 on the subject 42. Initially, the two sites 140.1 and 142.1 are simultaneously exposed by pixel elements P1 and P50, respectively, of the pixel panel 38. The pixel elements P1 and P50 are located at a row R0 and columns C1 and C0, respectively, of the pixel panel 38. This row and column designation is arbitrary, and has been identified in the present embodiment to clarify the example. The following discussion will focus primarily on site 140.1. It is understood, however, that the methods discussed herein are typically applied to multiple sites of the subject, including the site 142.1, but further illustrations and discussions with respect to site 142.1 will be avoided for the sake of clarity.

[0049] As can be clearly seen in FIG. 9, the pixel panel 38 is angled with respect to the subject 42 and the scan direction 136. As the system 30 scans, pixel element P11 would normally be projected directly on top of site 140.1. However, as shown in FIG. 10.2, the pixel element P11 exposes at a location 140.11 that is slightly offset in the y direction (or −y direction) from the site 140.1. As the system 30 continues to scan, pixel elements P12-P14 are exposed on offset locations 140.12-140.14, respectively, shown in FIGS. 10.3-10.5, respectively. Pixel elements P11-P14 are on adjacent consecutive rows R1, R2, R3, R4 of column C1 of the pixel panel 38.

[0050] In the present embodiment, the scanning motor 52 moves the stage 44 (and hence the subject 42) a distance of l, the length of the pixel site 140.1, for each projection. To provide the offset discussed above, the panel motor 55 moves the pixel panel 38 an additional distance of l/(N−1) for each projection. (N=5 in the present example). Therefore, a total relative movement SCAN STEP for each projection is:

[0051] SCAN STEP=l+l/(N−1).  (4)

[0052] In another embodiment, the offset may go in the opposite direction, so that the total relative movement SCAN STEP for each projection is:

[0053] SCAN STEP=l−l/(N−1).  (5)

[0054] In some embodiments, the panel motor 55 is not needed. Instead, the scanning motor 52 moves the stage the appropriate length (equation 4 or 5, above).

[0055] Once N locations have been exposed, the next pixel elements being projected onto the desired locations are of an adjacent column. With reference to FIG. 10.6, in the present example, a pixel element P2 at row R5, column C2 exposes a location 140.2 that is slightly offset in the x direction (or −x direction, depending on whether equation 4 or 5 is used) from the site 140.1. As the system 30 continues to scan, pixel elements P21-P24 are exposed on offset locations 140.21-140.24, respectively, shown in FIGS. 10.7-10.10, respectively. Pixel elements P21-P24 are on adjacent consecutive rows R6, R7, R8, R9 of column C2 of the pixel panel 38.

[0056] Once N more pixel locations have been exposed, the next pixel elements being projected onto the desired locations are of yet another adjacent column. With reference to FIG. 10.11, in the present example, a pixel element P3 at row R10, column C3 exposes a location 140.3 that is slightly offset in the x direction (or −x direction, depending on whether equation 4 or 5 is used) from the location 140.2. As the system 30 continues to scan, pixel elements P31-P34 are exposed on offset locations 140.31-140.34, respectively, shown in FIGS. 10.12-10.15, respectively. Pixel elements P31-P34 are on adjacent consecutive rows R11, R12, R13, R14 of column C3 of the pixel panel 38.

[0057] The above process repeats to fully scan the desired overlapped image. With reference to FIG. 10.16, in the present example, a pixel element P4 at row R15, column C4 exposes a location 140.4 that is slightly offset in the x direction (or −x direction, depending on whether equation 4 or 5 is used) from the location 140.3. As the system 30 continues to scan, pixel elements P41-P44 are exposed on offset locations 140.41-140.44, respectively, shown in FIGS. 10.17-10.20, respectively. Pixel elements P41-P44 are on adjacent consecutive rows R16, R17, R18, R19 of column C4 of the pixel panel 38.

[0058] Referring now to FIG. 11, in another embodiment of the present invention, the photolithography system 30 utilizes a unique optic system 150 in addition to the lens system 40. The optic system 150 is discussed in detail in U.S. patent Ser. No. 09/480,796, which is hereby incorporated by reference. It is understood that the lens system 40 is adaptable to various components and requirements of the photolithography system 30, and one of ordinary skill in the art can select and position lenses appropriately. For the sake of example, a group of lenses 40aand an additional lens 40bare configured with the optic system 150.

[0059] The optic system 150 includes a grating 152 and a point array 154. The grating 152 may be a conventional shadow mask device that is used to eliminate and/or reduce certain bandwidths of light and/or diffractions between individual pixels of the pixel panel 38. The grating 152 may take on various forms, and in some embodiments, may be replaced with another device or not used at all.

[0060] The point array 154 is a multi-focus device. There are many types of point arrays, including a Fresnel ring, a magnetic e-beam lens, an x-ray controlled lens, and an ultrasonic controlled light condensation device for a solid transparent material.

[0061] In the present embodiment, the point array 154 is a compilation of individual microlenses, or microlens array. In the present embodiments, there are as many individual microlenses as there are pixel elements in the pixel panel 38. For example, if the pixel panel 38 is a DMD with 600×800 pixels, then the microlens array 154 may have 600×800 microlenses. In other embodiments, the number of lenses may be different from the number of pixel elements in the pixel panel 38. In these embodiments, a single microlens may accommodate multiple pixels elements of the DMD, or the pixel elements can be modified to account for alignment. For the sake of simplicity, only one row of four individual lenses 154a, 154b, 154c, 154dwill be illustrated. In the present embodiment, each of the individual lenses 154a, 154b, 154c, 154dis in the shape of a rain drop. This shape provides specific diffraction benefits that will be discussed below. It is understood, however, that shapes other than those illustrated may also be used.

[0062] Similar to the lens system 40 of FIG. 1, the optic system 150 is placed between the pixel panel 38 and the subject 42. For the sake of example, in the present embodiment, if the pixel panel 38 is a DMD device, light will (selectively) reflect from the DMD device and towards the optic system 150. If the pixel panel 38 is a LCD device, light will (selectively) flow through the LCD device and towards the optic system 150. To further exemplify the present embodiment, the pixel panel 38 includes one row of elements (either mirrors or liquid crystals) for generating four pixel elements.

[0063] In continuance with the example, four different pixel elements 156a, 156b, 156c, 156dare projected from each of the pixels of the pixel panel 38. In actuality, the pixel elements 156a, 156b, 156c, 156dare light beams that may be either ON or OFF at any particular instant (meaning the light beams exist or not, according to the pixel-mask pattern), but for the sake of discussion all the light beams are illustrated.

[0064] The pixel elements 156a, 156b, 156c, 156dpass through the lens system 40aand are manipulated as required by the current operating conditions. As discussed earlier, the use of the lens system 40aand 40bare design options that are well understood in the art, and one or both may not exist in some embodiments. The pixel elements 156a, 156b, 156c, 156dthat are manipulated by the lens system 40aare designated 158a, 158b, 158c, 158d, respectively.

[0065] The pixel elements 158a, 158b, 158c, 158dthen pass through the microlens array 154, with each beam being directed to a specific microlens 154a, 154b, 154c, 154d, respectively. The pixel elements 158a, 158b, 158c, 158dthat are manipulated by the microlens array 154 are designated as individually focused light beams 160a, 160b, 160c, 160d, respectively. As illustrated in FIG. 11, each of the light beams 160a, 160b, 160c, 160dare being focused to focal points 162a, 162b, 162c, 162dfor each pixel element. That is, each pixel element from the pixel panel 38 is manipulated until it focuses to a specific focal point. It is desired that the focal points 162a, 162b, 162c, 162dexist on the subject 42. To achieve this goal, the lens 40bmay be used in some embodiments to refocus the beams 160a, 160b, 160c, 160don the subject 42. FIG. 11 illustrates focal points 162a, 162b, 162c, 162das singular rays, it being understood that the rays may not indeed be focused (with the possibility of intermediate focal points, not shown) until they reach the subject 42.

[0066] Continuing with the present example, the subject 42 includes four exposure sites 170a, 170b, 170c, 170d. The sites 170a, 170b, 170c, 170dare directly associated with the light beams 162a, 162b, 162c, 162d, respectively, from the microlenses 154a, 154b, 154c, 154d, respectively. Also, each of the sites 170a, 170b, 170c, 170dare exposed simultaneously. However, the entirety of each site 170a, 170b, 170c, 170dis not exposed at the same time.

[0067] Referring now to FIG. 12, the maskless photolithography system 30 with the optic system 150 can also performs two-dimensional digital scanning, as discussed above with reference to FIG. 8. For example, the image from the pixel panel 38 may be aligned at the angle □ (equations 2 and 3, above) with the scan direction 136.

[0068] Referring also to FIGS. 13, the present embodiment works very similar to the embodiments of FIGS. 9-10. However, instead of a relatively large location being exposed, the pixel elements are focused and exposed to a relatively small point (e.g., individually focused light beams 162a, 162b, 162c, 162dfrom FIG. 11) on the sites 170a, 170b, 170c, 170d.

[0069] First of all, the pixel element 156aexposes the individually focused light beam 162aonto the single site 170aof the subject 42. The focused light beam 162aproduces an exposed (or unexposed, depending on whether the pixel element 156ais ON or OFF) focal point PT1. As the system 30 scans, pixel element 156bexposes the individually focused light beam 162bonto the site 170a. The focused light beam 162bproduces an exposed (or unexposed) focal point PT2. Focal point PT2 is slightly offset from the focal point PT1 in the y direction (or −y direction). As the system 30 continues to scan, pixel elements 156cand 156dexpose the individually focused light beams 162cand 162d, respectively, onto the site 170a. The focused light beams 162cand 162dproduce exposed (or unexposed) focal points PT3 and PT4, respectively. Focal point PT3 is slightly offset from the focal point PT2 in the y direction (or −y direction), and focal point PT4 is similarly offset from the focal point PT3.

[0070] Once N pixel elements have been projected, the next pixels being projected onto the desired sites are of an adjacent column. This operation is similar to that shown in FIGS. 10.6-10.20. The above process repeats to fully scan the desired overlapped image on the site 170a.

[0071] It is understood that while light beam 162ais being exposed on the site 170a, light beam 162bis being exposed on the site 170b, light beam 162cis being exposed on the site 170c, and light beam 162dis being exposed on the site 170d. Once the system 30 scans one time, light beam 162ais exposed onto a new site (not shown), while light beam 162bis exposed on the site 170a, light beam 162cis exposed on the site 170b, and light beam 162dis exposed on the site 170c. This repeats so that the entire subject can be scanned (in the y direction) by the pixel panel 38.

[0072] It is further understood that in some embodiments, the subject 42 may be moved rapidly while the light beams (e.g., 162a-d) transition from one site to the other (e.g., 170a-170d, respectively), and slowly while the light beams are exposing their corresponding sites.

[0073] By grouping several pixel panels together in the x-direction, the entire subject can be scanned by the pixel panels. The computer system 36 can keep track of all the data provided to each pixel panel to accommodate the entire scanning procedure. In other embodiments, a combination of scanning and stepping can be performed. For example, if the subject 42 is a wafer, a single die (or group of die) can be scanned, and then the entire system 30 can step to the next die (or next group).

[0074] The example of FIGS. 11-13 are limited in the number of pixel elements for the sake of clarity. In the figures, each focal point has a diameter of about 2 the length l or width w of the site 170a. Since N=4 in this example, the overlap spacing is relatively large and the focal points do not overlap very much, if at all. As the number of pixel elements increase (and thus N increases), the resolution and amount of overlapping increase, accordingly.

[0075] For further example, FIG. 14 illustrates a site 220 that has been exposed by 600 pixel elements with focal points PT1-PT600 (e.g., from a 600×800 DMD). As can be seen, the focal points PT1-PT600 are arranged in an array (similar to equation 1, above) of:

[0076] (M,N)=20 focal points×30 focal points.  (6)

[0077] By selectively turning ON and OFF the corresponding pixel elements, a plurality of structures 222, 224, 226 can be formed on the site 220. It is noted that structures 222-226 have good resolution and can be drawn to various different shapes, including diagonal. It is further noted that many of the focal points on the periphery of the site 220 will eventually overlap with focal points on adjacent sites. As such, the entire subject 42 can be covered by these sites.

[0078] Alternatively, certain focal points or other types of exposed sites can be overlapped to provide sufficient redundancy in the pixel panel 38. For example, the same 600 focal points of FIG. 14 can be used to produce an array of:

[0079] (M,N)=20 focal points×15 focal points.  (7)

[0080] By duplicating the exposure of each focal point, this redundancy can accommodate one or more failing pixel elements in the pixel panel 38.

[0081] Referring now to FIG. 15, as discussed above, the pixel panel 38 may be rotated by an angle with respect to the subject 42 (angle θ, FIG. 8). This rotation is also described in U.S. Ser. No. 09/923,233, entitled “Real Time Data Conversion For A Digital Display” filed on Aug. 3, 2001, also assigned to Ball Semiconductor, Inc., and hereby incorporated by reference as if reproduced in its entirety. The pixel panel 38 scans the subject 42 in a direction indicated by an arrow 232 at a certain speed or “scan rate.”

[0082] Often, it is desirable to scale an image that is being exposed onto a subject. For example, if the subject is a flexible member, such as a textile, the image being exposed may need to be scaled to accommodate changes in the subject. Scaling may be performed vertically (in the direction of the arrow 232), horizontally (perpendicular to the arrow 232) or a combination of the two.

[0083] In one embodiment, vertical scaling may be achieved by adjusting the scan rate in relation to the frequency of the projected light. If the desired adjustment is less than the wavelength of the light, an optical interferometer position measurement system may be needed.

[0084] Horizontal scaling may also be achieved by “relocating” the data for the pixel element to a different pixel element that aligns with the focal point 234. The location of the different pixel element can be determined by recalculating the data locations on the pixel panel 38. This recalculation can be performed, for example, by the computer system 36 (FIG. 1). It is understood that the effectiveness of such a recalculation depends on whether the distance D is divisible by a spacing between two focal points. For example, if the focal point 234 is only one half of a pixel away from the current focal point 230, then a “closest” pixel element must be determined.

[0085] Referring generally to FIGS. 16, 17a, and 17b, in one embodiment, a method 300 can be used to scale the original focal point 230 to the scaled focal point 234. The method can be performed, for example, by the computer system 36 (FIG. 1), or a secondary computer.

[0086] A pixel element (not shown) is to be scaled for projection onto the subject 42 by the pixel panel 38. The pixel element is represented by three focal points 230 (the original focal point), 242 (the rotated focal point), and 234 (the scaled focal point), each of will be described in greater detail. Before scaling, the alignment and scan rate of the pixel panel 38 with respect to the subject 42 would be operable to project the pixel element onto the focal point 230. However, the pixel element is to be horizontally scaled by a distance “D” from the focal point 230 to the focal point 234 before projection.

[0087] To achieve this horizontal scaling, the method 300 begins with calculating the site of the focal point 230 in step 302 and an original angle of rotation θ_OSof the pixel panel 38 relative to the subject 42 in step 304. The site of the focal point 230 is calculated in step 306 and a new angle of rotation θ_NSof the pixel panel 38 relative to the subject 42 is calculated in step 308. The angle θ_NSdefines the angle to which the pixel panel should be rotated in order to align the pixel element with the focal point 242, which is horizontally aligned with the focal point 234. The pixel panel 38 is then rotated in step 310 to coincide with the angle θ_NS, which aligns the pixel element with the rotated focal point 242. To vertically align the pixel element with focal point 234, the scan rate of the pixel panel 38 relative to the subject 42 may be altered in step 312.

[0088] Referring now specifically to FIGS. 17aand 17b, the pixel panel 38 is originally aligned in a rotated position 246 relative to the subject 42. The pixel element may be referenced with respect to the pixel panel 38 using a two dimensional coordinate system (the pixel panel coordinate system) comprising an x-axis X_DMDparallel with the top and bottom edges of the pixel panel 38, and a y-axis Y_DMDparallel with the left and right edges of the pixel panel 38. The pixel panel 38 is scanned relative to the subject 42 in a direction 248 which is substantially parallel to the y-axis Y_DMD. The angle of rotation between the original rotated position 248 and the subject 42 is denoted by θ_OS.

[0089] The pixel element may be referenced with respect to the subject 42 using a second two dimensional coordinate system (the subject coordinate system) comprising an x-axis X_Sparallel with the top and bottom edges of the subject 42, and a y-axis Y_Sparallel with the left and right edges of the subject 42. Utilizing the pixel panel and subject coordinate systems enables the calculation of various aspects of the focal points 230, 234.

[0090] The original focal point 230 may be calculated in the subject coordinate system using the equations:

[0091] X_S=X_DMD*cos(θ_OS)+Y_DMD*sin(θ_OS);  (8)

[0092] Y_S=X_DMD*sin(θ_OS)−Y_DMD*cos(θ_OS).  (9)

[0093] Horizontally shifting the pixel element the distance D from the focal point 230 to the focal point 234 is accomplished by first rotating the pixel panel 38. In the present illustration, this rotation occurs in a clockwise manner. Before the rotation occurs, the coordinates of the desired focal point 234 and a new angle of rotation θ_NSbetween the pixel panel 38 and the subject 42 may be calculated in the subject coordinate system using the equations:

[0094] D =X_DMD*(cos(θ_NS)−cos(θ_OS));  (10)

[0095] X_S=X_DMD*cos(θ_NS)+Y_DMD*sin(θ_NS);  (11)

[0096] Y_S=X_DMD*sin(θ)−Y_DMD*cos(θ_NS).  (12)

[0097] Accordingly, the pixel panel 38 can be rotated through an angle θ_DIFF, which may be calculated as the difference between θ_OSand θ_NSor, in equation form,

[0098] θ_DIFF=θ_OS−θ_NS  (13)

[0099] Therefore, rotating the pixel panel 38 in a clockwise direction through the angle θ_DIFFwill position the pixel panel at the position 250. Accordingly, the pixel element will be projected onto the rotated focal point 242. As described previously, the focal point 242 is horizontally aligned with the desired focal point 234, but is not vertically aligned. Vertical alignment may be achieved by altering the scan rate of the pixel panel 38 relative to the subject 42. The vertical distance between the focal point 242 and the focal point 234 may be calculated in a manner using the pixel panel and subject coordinate systems as previously described. This enables vertical alignment of the pixel element and completes the scaling process.

[0100] Referring now to FIGS. 18 and 19, in another embodiment, the pixel panel 38 is moving relative to the subject 42 in a direction 252. The pixel panel 38 is to project a pixel element (not shown) onto a focal point 254. However, the focal point 254 is inaccessible to the pixel panel 38 as illustrated in FIG. 18, where the focal point 254 is a distance “D” away from the pixel panel 38. Such inaccessibility may be caused, for example, by the pixel panel's alignment relative to the subject 42, by the expansion or contraction of the subject 42, or by a combination of these and/or other factors.

[0101] To properly project the pixel element onto the focal point 254, the pixel panel 38 may be moved so that its projection area includes the focal point 254. This may be accomplished by calculating coordinates for the focal point 254 using coordinate systems relative to the pixel panel 38 and/or the subject 42. Such calculations may be accomplished as described in reference to FIGS. 16 and 17. For example, the original location 230 and the scaled location 234 discussed with FIGS. 16 and 17 may be a particular pixel of the pixel panel 38 and the focal point 234, respectively. Once the calculations are complete, the pixel panel 38 may be rotated so as to encompass the focal point 234 as illustrated in FIG. 19.

[0102] While the invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing form the spirit and scope of the invention. For example, the pixel panel 38 may be rotated in a counterclockwise manner to position the pixel element. In addition, a pixel element may be vertically aligned prior to aligning it horizontally. In some embodiments, certain calculations may be performed during the rotation of the pixel panel 38 and/or alteration of the scan rate, while in other embodiments the calculations may be completed before any actual physical alignment is undertaken. Additionally, a single coordinate system may be utilized for both the pixel panel 38 and the subject 42. In other embodiments, the third angle may be omitted from the calculations. Therefore, the claims should be interpreted in a broad manner, consistent with the present invention.