METHOD AND DEVICE FOR THE SIMULATION OF A PHOTOLITHOGRAPHIC PROCESS FOR GENERATING A WAFER STRUCTURE
20170228477 · 2017-08-10
Inventors
Cpc classification
G03F7/705
PHYSICS
International classification
Abstract
A method for the simulation of a photolithographic process for generating a wafer structure includes providing an aerial image of a region of a mask that includes the mask structure, prescribing a range of intensities, determining auxiliary or potential wafer structures for different threshold values within the range of intensities, determining the number of structure elements for each of the auxiliary or potential wafer structures, determining a stability range consisting of successive threshold values from the threshold values that were used for the determination of auxiliary or potential wafer structures, within the stability range the number of structure elements of the auxiliary or potential wafer structures remaining constant or lying within a prescribed range, and determining the wafer structure on the basis of the aerial image and a threshold value within the stability range. A microscope for carrying out the method is also provided.
Claims
1. A method for the simulation of a photolithographic process for generating a wafer structure on the basis of a prescribed mask structure, comprising the steps of: providing an aerial image of a region of a mask that includes the mask structure, prescribing a range of intensities, determining auxiliary wafer structures or potential wafer structures for different threshold values within the range of intensities, determining the number of structure elements for each of the auxiliary wafer structures or potential wafer structures, determining a stability range consisting of successive threshold values from the various threshold values that were used for the determination of auxiliary wafer structures or of potential wafer structures, within the stability range the number of structure elements of the auxiliary wafer structures or of the potential wafer structures remaining constant or lying within a prescribed range, and determining the wafer structure on the basis of the aerial image and a threshold value within the stability range.
2. The method according to claim 1, comprising the step of: determining as a threshold value a target threshold value that lies within or in the middle of the stability range.
3. The method according to claim 1, wherein the aerial image is determined by being recorded by a microscope or is simulated from the prescriptions for the structure of the region of the mask.
4. The method according to claim 1, wherein the determination of the wafer structure or of the auxiliary wafer structure or the potential wafer structures from the aerial image comprises subdividing the aerial image into first regions and second regions on the basis of the threshold value or the target threshold value.
5. The method according to claim 4, wherein locations of the aerial image are assigned to the first regions if intensity values of the aerial image are greater than the threshold value or the target threshold value, while locations of the aerial image are assigned to the second regions if the intensity values are less than the threshold value or the target threshold value.
6. The method according to claim 5, wherein transparent or reflective structure elements are formed as contiguous regions of the first regions and non-transmissive or absorbent structure elements are formed as contiguous regions of the second regions.
7. The method according to claim 1, comprising the step of: determining the wafer structure from a simulation of the exposure and development of the light-sensitive layer of a wafer on the basis of the aerial image and the target threshold value.
8. The method according to claim 1, comprising the step of: trimming the peripheral region of the aerial image, cutting edges at which the fluctuation of the intensity along the cutting edges lies within a prescribed range being chosen, this step being performed before determining the number of structure elements.
9. The method according to claim 1, wherein auxiliary wafer structures or potential wafer structures are determined for at least 50 or 40 or 30 different threshold values.
10. The method according to claim 1, wherein a number of stability ranges are determined for a mask structure.
11. The method according to claim 10, comprising the step of: determining a preferred stability range from a number of stability ranges, the stability range within which the wafer structure has the greatest number or a prescribed number of structure elements or comprises the greatest range of intensities being chosen as the preferred stability range.
12. The method according to claim 10, comprising the step of: determining a preferred stability range from a number of stability ranges, the stability range which comes closest to or is greater than or less than a prescribed ratio of the number of transparent structure elements and the number of non-transmissive structure elements being chosen as the preferred stability range.
13. The method according to claim 10, wherein a structure type of at least one of the structure elements is determined for at least two stability ranges, the stability range for which the determined structure type corresponds to a prescribed structure type being chosen as the preferred stability range.
14. A method for determining a threshold value for the determination of a mask structure, comprising the steps of: providing an aerial image of the mask structure, prescribing a range of intensities, prescribing different threshold values within the range of intensities, determining an auxiliary wafer structure or potential wafer structure for each of the threshold values, determining the number of structure elements for each of the auxiliary wafer structures or potential wafer structures, determining a stability range consisting of successive threshold values within the range of intensities for which the number of structure elements of the auxiliary wafer structures or potential wafer structures lies within a prescribed range or remains constant, and determining the threshold value as a threshold value within the stability range.
15. The method according to claim 14, comprising the step of: determining as a threshold value a target threshold value that lies within or in the middle of the stability range.
16. The method according to claim 14, wherein the aerial image is determined by being recorded by a microscope or is simulated from the mask structure.
17. The method according to claim 14, wherein the determination of the auxiliary wafer structure or potential wafer structure from the aerial image comprises subdividing the aerial image into first regions and second regions on the basis of the threshold value.
18. The method according to claim 17, wherein locations of the aerial image are assigned to the first regions if intensity values of the aerial image are greater than the threshold value or the target threshold value, while locations of the aerial image are assigned to the second regions if the intensity values are less than the threshold value or the target threshold value.
19. The method according to claim 17, wherein transparent or reflective structure elements are formed as contiguous regions of the first regions and non-transmissive or absorbent structure elements are formed as contiguous regions of the second regions.
20. The method according to claim 14, comprising the step of: trimming the peripheral region of the aerial image, cutting edges at which the fluctuation of the intensity along the cutting edges lies within a prescribed range being chosen, this step being performed before determining the number of structure elements.
21. The method according to claim 14, wherein auxiliary wafer structures or potential wafer structures are determined for at least 50 or 40 or 30 different threshold values.
22. The method according to claim 14, wherein a number of stability ranges are determined for a mask structure.
23. The method according to claim 22, comprising the step of: determining a preferred stability range from a number of stability ranges, the stability range within which the wafer structure has the greatest number or a prescribed number of structure elements or comprises the greatest range of intensities being chosen as the preferred stability range.
24. The method according to claim 22, comprising the step of: determining a preferred stability range from a number of stability ranges, the stability range which comes closest to or is greater than or less than a prescribed ratio of the number of transparent structure elements and the number of non-transmissive structure elements being chosen as the preferred stability range.
25. The method according to claim 22, wherein a structure type of at least one of the structure elements is determined for at least two stability ranges, the stability range for which the determined structure type corresponds to a prescribed structure type being chosen as the preferred stability range.
26. A microscope for determining a wafer structure of a mask, having: a light source and an illumination optical unit for illuminating the mask, an imaging optical unit for projecting an image of the mask onto a detector, and a computing unit for reading out the aerial image from the detector, the computing unit being programmed for carrying out the method according to claim 1.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0066] The invention is described and explained in greater detail below on the basis of some selected exemplary embodiments and with reference to the drawings.
[0067] In the figures:
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DETAILED DESCRIPTION
[0077] The construction of a microscope 1, which is suitable for the investigation of masks, is explained on the basis of
[0078] Referring to
[0079] For recording an aerial image of the intensity distribution in the pupil plane 35 of the illumination optical unit 30, a Bertrand lens 16 is introduced into the path of rays of the microscope 1 by a drive 17, controlled by the computing unit 40. The aerial image is stored in the memory of the computing unit 40 as a first matrix with constant resolution.
[0080] For recording focus stacks or Z-stacks, an image is recorded in the best focal plane and further images are recorded in parallel planes that are at a distance from the best focal plane in the Z direction. Images are recorded above and below the best focal plane.
[0081] Microscopes such as the microscope 1 described are used for the investigation of masks in lithography as a mask inspection microscope or as position measuring devices.
[0082] A further microscope that is not represented operates at the wavelength of 13.5 nm. It serves for the investigation of so-called EUV masks.
[0083] For the evaluation of the aerial images, the program MatLab, sold by the company MathWorks, Natick, Mass., is used.
[0084] The determination of the aerial image is performed by recording an aerial image by the microscope 1 or by simulation of an aerial image taken from a prescribed mask structure by the computing unit 40.
[0085] The intensities of an aerial image are normalized and, after the normalization, specified as a percentage or as values in the range between 0 and 1. The measured values I.sub.m of the intensities are determined in relation to the intensity I.sub.clear of the aerial image of a mask without a structure, i.e. with maximum transmissivity for illumination radiation, i.e. I=I.sub.m/I.sub.clear.
[0086] In a first optional step of the method, the peripheral regions of the aerial image are trimmed in order to remove structures that are only partially present in the image (54). The trimming is performed in such a way that the influence of structures that are only partially present in the image is avoided. These would falsify the number of structure elements.
[0087] Intensity profiles are determined along an edge of the aerial image. This determination is performed for a peripheral region of a prescribed width. The width of the region may be for example 10 pixels or 20 or 50 pixels. Within this range, an intensity profile is determined for each row of pixels. The intensity profile takes the form of a one-dimensional matrix or one-dimensional array. Consequently, intensity profiles that are parallel to one another are determined. In one variant, for the determination of intensity profiles a number of parallel intensity profiles are combined by forming the average of the respective values. A characteristic variable that is a criterion for the number of incomplete structure elements is determined for each of the intensity profiles.
[0088] For example, the following variables may be determined as the characteristic variable: the standard deviation of the intensities of the intensity profile, the sum of all of the intensities of the intensity profile, the histogram of the intensities of the intensity profile, the entropy of the intensity profile or the standard deviation thereof.
[0089] For the determination of a histogram, all of the intensity values of the same magnitude are counted for all possible intensity values within the intensity profile. The results are plotted as the number of intensity values occurring against the magnitude of the intensity values. The function imhist(I)=[counts, binLocations] of the Matlab program is used for the method. In this case, the number of respective intensity values in counts and the associated intensity values in binLocations are returned. I is the intensity profile.
[0090] The entropy E of an intensity profile is determined from the histogram according to the formula: E=−sum(counts*log.sub.2(counts)). This corresponds to the MatLab function entropy(I).
[0091] Starting from the periphery of an aerial image, the characteristic variable, such as for example the entropy, is then determined within the region for each of the intensity profiles determined. From all of the intensity profiles, the intensity profile that has the lowest entropy value is determined. This intensity profile is established as a cutting edge. Cutting edges are determined in this way for all four peripheries of the aerial image.
[0092] Regions of the aerial image that lie outside the cutting edges are removed. In a variant of the method, first an auxiliary aerial image that is identical to the aerial image is created and this auxiliary aerial image is trimmed. The auxiliary aerial image is then used for the further evaluation, while the untrimmed aerial image is taken as a basis for the representation of the wafer structure.
[0093] In a further step of the method, an intensity range within which stability ranges of a wafer structure are to be determined is prescribed.
[0094] The intensity range may be chosen from 0 to 100% of the intensities of the aerial image. Depending on the structure type, smaller ranges may also be chosen. Ranges of intensity values may also be excluded.
[0095] The process 50 includes prescribing of threshold values within an intensity range (56). For example, the chosen intensity range is divided into intervals of the same size. For each of the threshold values thus determined, an auxiliary wafer structure or potential wafer structure is determined (58). For each auxiliary wafer structure or potential wafer structure, the number of structure elements is determined (60). In a variant of the method, the intervals of the intensity values may also be varied as dependent on the variation in the number of structure elements. When there is a stronger variation of the number of structure elements in dependence on the intensity values, smaller intervals of the intensity values are then chosen.
[0096] One of the methods mentioned for determining wafer structures, either the threshold value method or a resist simulation, is used for the determination of a wafer structure or an auxiliary wafer structure or potential wafer structure.
[0097] In the case of the threshold value method, locations of the aerial image at which intensity values of the aerial image are greater than the threshold value are assigned to the first regions, while locations of the aerial image are assigned to the second regions if the intensity values are less than the respective threshold value. Intensity values that are equal to the threshold value may be assigned either to the first regions or to the second regions.
[0098] A threshold value is applied to an aerial image in such a way that regions for which the intensity values lie below the threshold value are marked as “non-transmissive” and regions for which the intensity values lie above the threshold value are marked as “transparent”. In the case of reflective masks, the regions are marked on the basis of the intensity values as “absorbent” and “reflective”. There is consequently an assignment of the intensity values to first regions and to second regions. The wafer structure may then be graphically represented for example by “white” for regions of the mask marked as transparent or reflective and “black” for regions of the mask marked as non-transmissive or absorbent. The “black” and “white” markings may also be used the opposite way. This is dependent on the type of light-sensitive lacquer (resist) that is used on the wafer. A positive resist or a negative resist may be used, either the regions that were exposed to illumination radiation with an intensity above the threshold value being etched away or the regions that were exposed to illumination radiation with an intensity below the threshold value being etched away. The other regions respectively remain.
[0099] A suitable method for resist simulation is disclosed for example in the already cited German laid-open specification DE19757696. The assignment of the intensity values to first regions and to second regions is performed by this method. The graphical representation and the further evaluation are performed as above.
[0100] In a further step of the method, the number of structure elements is determined for each of the auxiliary wafer structures or potential wafer structures.
[0101] Contiguous first and second regions of transparent or non-transmissive structure elements of each auxiliary wafer structure or potential wafer structure are determined. This is performed by the functions bwlabel, bwlabeln and bwconncomp of the MatLab program mentioned.
[0102] For the assessment of the stability, the number of structure elements is determined. Different variables may be determined as the number of structure elements to be taken into consideration. The sum of all the transparent and non-transmissive structure elements may be determined. The sum of all the transparent structure elements or the sum of all the non-transmissive structure elements may be determined. Only structure elements of a prescribed size may be taken into consideration in the determination of the sum. Only structure elements below or above a prescribed size may be taken into consideration.
[0103] In a variant of the method, only structure elements that have a prescribed structure type or a number of prescribed structure types are counted.
[0104] The assignment of structure types to structure elements of wafer structures is performed by using the design software CATS from the company Synopsis Inc., Mountain View, Calif.
[0105] Structure types that are characterized by structure features are prescribed. The structure features are assigned properties such as “non-transmissive” or “transparent” or values of ranges of measured variables. These properties or ranges of values are nominal values or admissible tolerance ranges that are prescribed for a structure type. Examples of structure types, structure features and possible values and ranges of values are given in Table 1.
TABLE-US-00001 TABLE 1 End to end Contact hole Lines and spaces (End-to-End) (Contact Hole) (Lines and Spaces) Structure type (MM) (BOXROT) (CDR) Tone Non- transparent transparent (TONE) transmissive (CLEAR) (CLEAR) (OPAQUE) Contour open closed open (CONTOUR) (OPEN) (CLOSED) (OPEN) Width 0.09-2 μm 0.08-0.5 μm 0.5-2 μm (NM_WIDTH) Critical 0.09-0.6 μm 0.11-0.5 μm 0.19-0.35 μm dimension (CD) Aspect ratio 1-60 1-3 2-11 (ASPECT RATIO)
[0106] The respective technical terms and also the terms in the CATS design environment are given in brackets. The numerical values are examples.
[0107] The structure type of a structure element is determined automatically by the CATS software. In this program, corresponding image processing and analysis algorithms are implemented.
[0108] Decision criteria that form a correlation data record are prescribed for the automatic determination of the structure types. The decision criteria may have a hierarchical structure. Decision nodes may be prescribed for structure features. At a decision node, a structure feature, such as for example the tone, is prescribed and the decision concerning at least two alternative paths is taken in dependence on the value of the structure feature. In an example, for the value “non-transmissive” of the tonality structure feature, the end-to-end structure type is directly assigned. If the tonality structure feature has the value “transparent”, in the next step the structure feature “aspect ratio” is checked. A threshold value is prescribed there. If the value is below the threshold value, the lines and spaces structure type is assigned; if the value lies above the threshold value, the contact hole structure type is assigned.
[0109] In a further step of the method, stability ranges are determined (62). These are intensity ranges within which the structure does not vary, or only little. Ranges within which the number of structure elements remains constant or lies within a prescribed range or varies from the mean value within a prescribed deviation are determined from the threshold values and the respective number of structure elements.
[0110] A target threshold value may be determined from a stability range (64). This is the threshold value in the middle of the stability range. The target threshold value does not necessarily have to be a threshold value that has already been used in the determination of the stability range. Known interpolation methods may also be used for the determination.
[0111] The wafer structure to be simulated is determined from the aerial image and the target threshold value either by the threshold value method or by a resist simulation. While the auxiliary wafer structures or potential wafer structures follow from the respective individual threshold values, the wafer structure with the target threshold value is calculated and thus describes the result of the actual exposure operation as well as possible. This wafer structure may then be used in subsequent analyses, for example in examinations of the mask for defects. These are then displayed on a monitor of the computing unit and may also be sent by e-mail.
[0112] It is possible that a number of stability ranges are obtained as a result of the analysis. A preferred stability range may be determined (64) from a number of stability ranges on the basis of one or more of the following conditions: [0113] The greatest stability range. [0114] The stability range that has the greatest number of structure features. The number may be obtained by the ways described above. [0115] The stability range that comprises a prescribed structure type or comprises or does not comprise a number of prescribed structure types. The determination of the structure types of the structure elements is performed as described above. [0116] The stability range that comes closest to a prescribed ratio of the number of transparent structure regions and the number of non-transmissive structure regions or is greater than the ratio or less than the ratio.
[0117] A wafer structure may be determined and displayed for the preferred stability range and the associated target threshold value.
[0118] The method is explained below on the basis of an example. The region of a mask that is to be investigated is a checkerboard pattern 101, as outlined in plan view in
[0119] Within the region 103, intensity profiles are determined in the direction of the mask edge 102d. An intensity profile consists here of a row of pixels along the mask edge. The entropy is calculated for each intensity profile. The dependence thus determined of the entropy on the distance of the intensity profile from the mask edge is shown in
[0120] The other three edges of the aerial image are trimmed in the same way.
[0121] Auxiliary wafer structures or potential wafer structures are determined for 50 intensity values that lie at equal intervals between 0 and 100%.
[0122] For each of the auxiliary wafer structures or potential wafer structures, the number of structure elements is determined. In this example, all of the structure elements are counted, irrespective of their properties. Particularly critical here is a threshold value of 50%. In this case, a checkerboard pattern is obtained. Regions with intensities above the threshold value, that is to say transparent regions, are in contact with the four closest transparent regions at precisely four points. Since a structure element is a contiguous transparent region, precisely one structure element would be obtained as the number. When there is a slight variation in the threshold value, some transparent regions could no longer be connected by the corners to the neighboring regions. Therefore, the number of structure elements would change greatly. In this example, therefore, especially the choice of a threshold value of 50% is very unstable.
[0123] With threshold values that deviate enough from 0%, 50% and 100%, the number of contiguous regions no longer changes. Successive regions of structure elements within which the number of structure elements remains constant are determined. The result shows two stability ranges of the same size. In
[0124] The potential wafer structure 115 for the first target threshold value within the first stability range is shown in
[0125] The potential wafer structure 116 for the second target threshold value within the second stability range is shown in
[0126] In the next step, the wafer structure can be selected on the basis of the prescribed structure type. “Contact hole” is prescribed as the structure type. This allows the suitable threshold value to be selected from the first and second target threshold values.
[0127] The features described above related to processing of data (for example, trimming peripheral regions of the aerial image and determining the threshold value within the stability range) can be performed by the computing unit 40. For example, the computing unit 40 can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The features related to the processing of data can be implemented in a computer program product tangibly embodied in an information carrier, e.g., in a machine-readable storage device, for execution by a programmable processor; and method steps can be performed by a programmable processor executing a program of instructions to perform functions of the described implementations by operating on input data and generating output. Alternatively or addition, the program instructions can be encoded on a propagated signal that is an artificially generated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal, that is generated to encode information for transmission to suitable receiver apparatus for execution by a programmable processor.
[0128] The described features related to processing of data can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, an input device, and an output device. A computer program is a set of instructions that can be used, directly or indirectly, in a computer to perform a certain activity or bring about a certain result. A computer program can be written in any form of programming language (e.g., Fortran, C, C++, Objective-C, Java), including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment.
[0129] Suitable processors for the execution of a program of instructions include, by way of example, both general and special purpose microprocessors, and the sole processor or one of multiple processors or cores, of any kind of computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memories for storing instructions and data. The computer can be a cloud server. Generally, a computer will also include, or be operatively coupled to communicate with, one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
[0130] To provide for interaction with a user, the features can be implemented on a computer having a display device such as a LCD (liquid crystal display), OLED (organic light emitting diode), or electronic ink monitor for displaying information to the user and a keyboard and a pointing device such as a mouse or a trackball by which the user can provide input to the computer. A touch screen can be provided for the user to interact with the computer. The computer may also have voice recognition functions to enable the user to interact with the computer by voice.
[0131] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, elements of one or more implementations may be combined, deleted, modified, or supplemented to form further implementations. As yet another example, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims.