EP1252652A1 - Procede de surveillance d'un processus de fabrication - Google Patents

Procede de surveillance d'un processus de fabrication

Info

Publication number
EP1252652A1
EP1252652A1 EP00904853A EP00904853A EP1252652A1 EP 1252652 A1 EP1252652 A1 EP 1252652A1 EP 00904853 A EP00904853 A EP 00904853A EP 00904853 A EP00904853 A EP 00904853A EP 1252652 A1 EP1252652 A1 EP 1252652A1
Authority
EP
European Patent Office
Prior art keywords
linear combination
matrix
parameter
determined
function
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00904853A
Other languages
German (de)
English (en)
Inventor
Ferdinand Bell
Dirk Knobloch
Jan Zimpel
Knut VOIGTLÄNDER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Infineon Technologies AG
Original Assignee
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Infineon Technologies AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV, Infineon Technologies AG filed Critical Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Publication of EP1252652A1 publication Critical patent/EP1252652A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/17Systems in which incident light is modified in accordance with the properties of the material investigated
    • G01N21/25Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L22/00Testing or measuring during manufacture or treatment; Reliability measurements, i.e. testing of parts without further processing to modify the parts as such; Structural arrangements therefor
    • H01L22/20Sequence of activities consisting of a plurality of measurements, corrections, marking or sorting steps
    • H01L22/26Acting in response to an ongoing measurement without interruption of processing, e.g. endpoint detection, in-situ thickness measurement
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L22/00Testing or measuring during manufacture or treatment; Reliability measurements, i.e. testing of parts without further processing to modify the parts as such; Structural arrangements therefor
    • H01L22/10Measuring as part of the manufacturing process
    • H01L22/12Measuring as part of the manufacturing process for structural parameters, e.g. thickness, line width, refractive index, temperature, warp, bond strength, defects, optical inspection, electrical measurement of structural dimensions, metallurgic measurement of diffusions

Definitions

  • the present invention relates to a method for monitoring a manufacturing process.
  • the present invention relates in particular to a method for monitoring a production process for processing a semiconductor substrate in semiconductor production.
  • Modern industrial production is generally characterized by a high degree of automation.
  • a high degree of automation is essential in order to be internationally competitive.
  • a large number of manufacturing processes and machining processes are used in the production and processing of semiconductor substrates to form integrated semiconductor circuits.
  • Deposition processes for producing material layers and etching processes for structuring these layers may be mentioned here as examples.
  • These manufacturing processes must always be monitored because, due to their complexity, unnoticed faults or poorly adapted process conditions can lead to incorrectly manufactured semiconductor circuits.
  • there is generally a desire to characterize the manufacturing process by analyzing certain measured variables determined during the manufacturing process in order to be able to intervene in a regulatory manner if necessary.
  • the etching time is a decisive parameter in order to achieve a high quality result. If the etching time is too short, the layer to be etched is only incompletely removed. If the etching is too long, for example, active areas are etched, or structures are under-etched. Both conditions must be avoided by suitable methods of detecting the correct end time.
  • a possible method for detecting the correct end time is known, for example, from US Pat. No. 5,877,032. It describes a method for determining the end point of a plasma etching process, in which the optical emission of the plasma is used to determine the end point.
  • the background of this method is the fact that during the etching process, a layer located on a substrate is etched through, thereby exposing the underlying substrate or the underlying layer.
  • the interaction of the etching gas with the exposed substrate or the exposed layer can be detected spectroscopically as a change in the emission spectrum of the plasma. According to US Pat. No. 5,877,032, this change is compared with a large number of predetermined reference curves and the comparison is used to infer the end point of the plasma etching process.
  • a method for determining the end point of a plasma etching process is also known from US Pat. No. 5,739,051.
  • the optical emission of the plasma is also used to determine the end point, emission lines which are characteristic of the interaction of the etching gas with the exposed substrate being used for the evaluation.
  • optical filters are used in industrial systems, depending on the chemical reactions taking place in the plasma, in order to be able to follow the temporal course of the intensities in predetermined wavelength ranges. This procedure is not practicable, especially in chambers where changing products with different chemical compositions are run. Detection of the end point in different optical areas requires JLM to H
  • ⁇ PJ rr a ⁇ rr H- 0 O * »rr CO 0- H- 0- J ⁇ OHHO ⁇ rr d CO PJ H- ⁇ t- 1 O ⁇ rr d ⁇ • ri - rr a ⁇ £> ⁇ . ⁇ 3 • Ü PH. c HO a PJ 3 CD ⁇ H H- "
  • a method for monitoring a manufacturing process which has the following steps:
  • At least one linear combination is formed from the multiplicity of measured variables, the weights of the linear combination being selected such that a predetermined curve shape is approximated, LO J to t P 1 P 1
  • Emission spectra generally contain very detailed information about the process on which the radiation emission is based, for example a chemical reaction.
  • very large amounts of data are obtained, from which the decisive information can only be extracted with great difficulty using conventional methods.
  • emission spectra can be used with the method according to the invention for online monitoring of manufacturing or processing processes. It is particularly preferred if the intensities of different wavelengths are used in a spectral range between 200 and 950 nm.
  • the emission spectrum of a plasma process is used.
  • Plasma etching processes for structuring material layers play an important role in semiconductor production. The dimensions of the structures produced depend crucially on the quality of the etching process used.
  • the emission spectrum of the plasma contains a lot of information that is necessary to control the plasma process.
  • Highly developed sensor systems such as the so-called “Optical Emission Spectroscopy (OES)” or the so-called “Residual Gas Analysis (RGA)” can be used to record the spectra. It is particularly preferred if the end time of the plasma process is determined as the parameter.
  • a step-like function is used as the predetermined curve shape.
  • Step-like functions such as a tangent hyperbolic function, can be used with corresponding evaluation algorithms. gorithms can be examined relatively easily to determine whether the step has already been completed or not, ie whether the value of the function has already jumped from a low value to a higher value. Accordingly, if the parameter to be determined is linked to the occurrence of the stage, the parameter can be determined relatively easily automatically. It is particularly preferred if the step-like function has at least one free parameter for adaptation to the parameter to be determined.
  • the measured variables are arranged in a matrix at the specified times and a main component analysis (“principal component analysis”) is carried out on the basis of this matrix
  • Principal component analysis is a method of expressing a matrix A by means of its principal vectors or principal components.
  • a number of methods can be used to calculate the main components. For example, the singular value decomposition (SVD) of matrix A can be calculated.
  • the eigenvalues and eigenvectors of the correlation matrix (A T A) of matrix A can also be calculated. laying a matrix such as the so-called "(nonlinear) partial least squares" of a matrix A can be used.
  • the main component analysis is preferably carried out with the aid of a singular value decomposition, so that the matrix A mn is decomposed into two orthogonal matrices U TM * " 'and V nxn and a diagonally populated matrix ⁇ with the singular values ⁇ x , where:
  • the so-called "left" eigenvectors u ⁇ form the matrix O mxm while the so-called “right” eigenvectors v form the matrix V nxn .
  • the singular values ⁇ x are ordered in size and represent the share that the associated dyadic product ⁇ v "1 ⁇ has in the formation of the total matrix A.
  • the dyadic products UiV ⁇ which have only small singular values ⁇ x , have in the As a rule, no information about the monitored process, and accordingly, matrices of measured variables that are actually measured are generally sufficiently well represented by the dyadic products U ⁇ V T j. With the 3 to 15 largest singular values ⁇ x .
  • a functional is minimized or maximized on the basis of the predetermined curve shape and the linear combination in order to determine the weights of the linear combination. It is particularly preferred if, by minimizing (or maximizing) the
  • Functiona is the main main components of the measurement matrix are determined. By minimizing (or maximizing) the function, those main components can be easily determined that must be taken into account in order to approximate the specified curve shape with sufficient accuracy. It is further preferred if the free parameter of the step-like function is determined by minimizing the function. In this way, an optimal signal curve for the measured variable to be determined can be determined in a self-consistent manner.
  • the linear combination is smoothed to determine the parameter.
  • the measured variables have a noise component, which can also be found in a linear combination of the measured variables. So that no misjudgment is made due to the noise, it is preferred to suppress the noise component by smoothing the linear combination to such an extent that the parameter can be determined correctly. It is particularly preferred if the smoothing of the linear combination is achieved by using a zero phase filter.
  • qualitative criteria such as the occurrence of a local maximum or the occurrence of a turning point, can be used to determine the parameter.
  • Qualitative criteria have the advantage over quantitative criteria, such as exceeding certain threshold values, that they depend to a lesser extent on the respective absolute size of the measured values and can therefore be used more robustly over a larger range of values.
  • the measured variables of a plurality of trial runs and / or production runs are used to determine the weights of the linear combination.
  • the measured variables of a plurality of trial runs and / or production runs are arranged in a matrix (block matrix) and a main component analysis is carried out on the basis of this matrix.
  • FIG. 1 shows a schematic representation of a device for carrying out a first embodiment of the method according to the invention
  • 3A-3C show the corresponding first three right eigenvectors of a spectrum matrix
  • 4 shows a graph of the achievable model quality as a function of the end time t E p and the number of main components taken into account
  • Fig. 10 shows the course of the corresponding conventional
  • FIG. 12 shows the time derivative of the linear combinations y (t) shown in FIG. 9 after filtering
  • FIG. 1 shows a schematic representation of a device for carrying out a first embodiment of the method according to the invention.
  • the essential components of this device are a reaction chamber 1, in which, for example, a plasma etching process (e.g. RIE) can be carried out.
  • the etching gas is fed into the reaction chamber 1 via an inlet 2, where it is ionized and converted into a plasma.
  • the plasma 9 is generated and maintained by a capacitively applied RF voltage, which is provided by an RF source 3.
  • the reaction products of the etching are removed from the reaction chamber 1 through an outlet 4.
  • An etching gas mixture of CF 4 , CHF 3 and argon is used as the etching gas, the plasma being improved in its homogeneity by a magnetic field (not shown) of approximately 60 gaus.
  • the power used to generate and maintain the plasma is approximately 1200 watts.
  • the pressure in the reaction chamber 1 is about 150 mtorr.
  • the plasma is used to etch contact holes in a silicon dioxide layer which is arranged on a silicon wafer 5.
  • the silicon wafer 5 is placed on a holder 6 in the reaction chamber 1.
  • the contact holes which are generally used to connect the diffusion areas (active areas) of the transistors, have a very small opening ratio.
  • the requirements for recognizing the correct end time of the etching at which the contact holes reach the silicon substrate are correspondingly high. If the etching time is too short, the contact holes are not opened completely and the transistors are not connected. If the etching time is too long, the active areas of the transistors are strongly etched. Both can lead to total failure of the integrated circuit. O LO) t HP 1
  • FIGS. 2A-2C show representations of the first three left eigenvectors u 0 ! the matrix ⁇ 0 ( ⁇ , t), ie the left eigenvectors u ° 1 with the three largest singular values ⁇ ° !
  • FIGS. 3A-3C show representations of the corresponding first three right eigenvectors v C ! the matrix ⁇ 0 ( ⁇ , t).
  • the columns u ° ! of the matrix U 0 can be interpreted as a basic wavelength pattern, while the columns v ° x of the matrix V 0 can be interpreted as a basic time signal.
  • y 0 (t) ⁇ , ⁇ 0 ( ⁇ , t) ⁇ u ⁇ c,.
  • the function y 0 (t) is a function of the time t, which is calculated using the coefficients Cj. can be adapted to a given curve shape.
  • the predetermined curve shape is selected so that the important parameter, in this case the end time of the etching, can be extracted relatively easily from the linear combination.
  • a typical example of such a curve shape is a tangent hyperbolic function:
  • the parameter ⁇ is a measure of the desired slope with which the function y M0 (t) jumps from its initial value ( «0) to its final value ( ⁇ 1).
  • this parameter is specified externally and is not a variable in the optimization that follows.
  • the parameter t EP specifies the point in time at which the function y M0 (t) jumps from its initial value ( «0) to its final value ( ⁇ 1).
  • This parameter t EP is not specified from the outside, but is determined in the optimization that follows, so that the end time obtained from the test run and the parameter t EP match as closely as possible. In this exemplary embodiment, this is achieved by minimizing the quality function Q. The following applies:
  • N ⁇ t (yMo (t, t EP ) - ⁇ t - y M0 (t ', t EP )) 2 .
  • ⁇ t (or ⁇ t -) stands for a sum of the respective function values at the specified times.
  • FIG. 4 shows a graph of the achievable model quality as a function of the end time t EP and the number of main components taken into account.
  • the optimal choice for the parameter t EP (the point at which the steepest end point signal can be generated) is found by a one-dimensional numerical optimization. It is expedient to use a superordinate grid search and then a local gradient-oriented optimization to find the optimal t E p opt (n) depending on the number of main components taken into account. In this way, disturbances caused by local minima can be avoided.
  • FIG. 5 shows a graph of the achievable model quality Q opt with optimal coefficients c op ! and t EP ⁇ pt depending on the number of main components considered.
  • the only parameter still to be determined - the number of main components to be taken into account - can finally be determined. 5 that an adequate model quality has already been achieved with 4 selected main components.
  • the trial etching is thus evaluated and the weights of the linear combination from the measured variables are defined.
  • An “end point pattern” u EP can now be formed from the selected main components on the right and the optimal coefficients c opc 1 :
  • FIG. 6 shows a representation of the end point pattern u EP .
  • the components U EP 3 of the end point pattern U EP are the weights sought for the linear combination of the intensities of the measured wavelengths of the emission spectrum.
  • a chemical interpretation can be assigned to the end point pattern u EP .
  • CN and H lines can be clearly seen in FIG. 6.
  • the emission spectrum of the plasma etching is measured continuously, as described with reference to FIG. 1.
  • a linear combination y (t) is now formed from the measured variables with the aid of the weights EP 3 . This can be done, for example, by creating a matrix ⁇ ( ⁇ , t) from the measured values and multiplying the end point pattern U EP by the transpose of this matrix ⁇ ( ⁇ , t) after each measurement time:
  • y (t) ⁇ ( ⁇ , t) ⁇ u EP .
  • FIG. 7 shows a representation of the linear combination y (t) for improved determination of the end time of a plasma etching. It can clearly be seen that the linear combination y (t) essentially has a step-like shape, which provides a much sharper signal that is more suitable for recognizing the correct end time. As a comparison, the corresponding conventional end point signal is shown in FIG. With this conventional end point signal, the correct end time must be determined by the location of the small local len maximum in the middle of the signal (about 80 seconds). Accordingly, the determination of the end time with the conventional methods is uncertain.
  • An evaluation of the linear combination y (t) shown in FIG. 7 now provides the desired end time of the plasma etching.
  • One way to evaluate the linear combination y (t) is to specify a threshold value (e.g. 0.6). If the linear combination y (t) exceeds the threshold value, the etching process can be ended either immediately or after a certain, predetermined post-etching time has elapsed.
  • threshold value is very easy to implement and provides satisfactory results for many processes. Unfortunately, this procedure for determining the parameter usually depends on the absolute sizes of the measured values. In the present example, reaching the threshold value depends, for example, on the total intensity of the measured radiation. However, the total intensity of the measured radiation is not known a priori, so that the correct end time cannot be determined exactly by specifying a threshold value.
  • the inflection point of the linear combination y (t), ie the maximum of the first derivative of the linear combination y (t) according to time, is used in the following to precisely determine the end time.
  • this turning point is essentially independent of the total intensity of the measured signal.
  • FIG. 11 shows the time derivative of the linear combinations y (t) shown in FIG. 9.
  • the first derivative of the linear combinations y (t) is also very noisy, so that the maximum of the first derivative cannot be determined in a simple manner.
  • the linear combinations y (t) are first filtered before the first time derivative is formed.
  • the filtering suppresses the noise component and the actual signal is more pronounced.
  • 12 shows the first derivative of the filtered linear combinations y (t). So that the maximum does not shift during filtering, the filtering is carried out with a so-called zero phase filter.
  • a number of methods or filters can be used to filter the linear combination y (t).
  • the time-discrete variant (duty cycle T a ) of a 1st order Butterworth filter (filter time T F ) was used.
  • This filter has the following transfer function G:
  • a filter time constant T F of 10s with a duty cycle T a of 2s was chosen.
  • the specific filtering is carried out by first applying the filter G to the signal y (t) to be filtered.
  • the intermediate signal y * thus generated is now used to compensate for the phase shift generated in the first filtering by means of a zero and pole mirroring from the filter G O LO to to P 1
  • the correct weights (coefficients) for the linear combination of the measured variables can be useful to include the results of several test runs or production runs in the determination of the weights (coefficients) for the linear combination.
  • the measured spectral matrices of several etchings e.g. at the beginning, in the middle and at the end of a so-called "wet clean cycle" of the reaction chamber
  • the measured spectral matrices of several etchings e.g. at the beginning, in the middle and at the end of a so-called "wet clean cycle" of the reaction chamber
  • the measurement variable matrices of the individual processes into a single, large block matrix.
  • the matrix U in turn contains the linearly independent spectral basic patterns Ui.
  • n different parameters t ⁇ p 3 but only one set of optimal coefficients c opt ! , from which an end point pattern u EP can be formed:
  • the weights U E P 3 thus obtained now contain the information from several etchings, so that methods can be used in a stable manner, for example, over a longer period of time.

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  • Life Sciences & Earth Sciences (AREA)
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  • Computer Hardware Design (AREA)
  • Spectroscopy & Molecular Physics (AREA)
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Abstract

La présente invention concerne un procédé de surveillance de processus de fabrication, qui, par combinaison linéaire de grandeurs de mesures avec des facteurs de pondération judicieusement sélectionnés, permet de produire un signal (optimal) permettant de déterminer la grandeur caractéristique correspondante. Cela permet de simplifier significativement l'extraction de la grandeur caractéristique à partir des grandeurs de mesure et, dans de nombreux cas, de rendre possible ladite extraction. Le procédé de l'invention permet en fait de traiter de grandes quantités de données de sorte que les informations importantes (grandeurs caractéristiques) peuvent être acquises pratiquement en temps réel ou en temps réel à partir des données.
EP00904853A 2000-01-25 2000-01-25 Procede de surveillance d'un processus de fabrication Withdrawn EP1252652A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/DE2000/000249 WO2001056072A1 (fr) 2000-01-25 2000-01-25 Procede de surveillance d'un processus de fabrication

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EP1252652A1 true EP1252652A1 (fr) 2002-10-30

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US7479395B2 (en) 2009-01-20
US20030008507A1 (en) 2003-01-09
WO2001056072A1 (fr) 2001-08-02

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