WO2004003664A1 - マスクおよびその検査方法並びに半導体装置の製造方法 - Google Patents
マスクおよびその検査方法並びに半導体装置の製造方法 Download PDFInfo
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- WO2004003664A1 WO2004003664A1 PCT/JP2003/008176 JP0308176W WO2004003664A1 WO 2004003664 A1 WO2004003664 A1 WO 2004003664A1 JP 0308176 W JP0308176 W JP 0308176W WO 2004003664 A1 WO2004003664 A1 WO 2004003664A1
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- thin film
- exposure
- inspection
- mask
- pattern
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Classifications
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F1/00—Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof
- G03F1/20—Masks or mask blanks for imaging by charged particle beam [CPB] radiation, e.g. by electron beam; Preparation thereof
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F1/00—Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof
- G03F1/38—Masks having auxiliary features, e.g. special coatings or marks for alignment or testing; Preparation thereof
- G03F1/44—Testing or measuring features, e.g. grid patterns, focus monitors, sawtooth scales or notched scales
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F1/00—Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof
- G03F1/68—Preparation processes not covered by groups G03F1/20 - G03F1/50
- G03F1/72—Repair or correction of mask defects
- G03F1/74—Repair or correction of mask defects by charged particle beam [CPB], e.g. focused ion beam
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F1/00—Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof
- G03F1/68—Preparation processes not covered by groups G03F1/20 - G03F1/50
- G03F1/82—Auxiliary processes, e.g. cleaning or inspecting
- G03F1/84—Inspecting
Definitions
- the present invention relates to a mask, an inspection method therefor, and a method for manufacturing a semiconductor device.
- the present invention relates to a mask used in a lithographic process in the manufacture of a semiconductor device, a method of inspecting the mask, and a method of manufacturing a semiconductor device.
- a transfer-type exposure method using charged particles called electron beam beams has been developed.
- a mask having a thin film region (membrane) is commonly used.
- the membrane on the mask surface side has a thickness of about 100 to 10 ⁇ m, and the transfer pattern is arranged on the membrane.
- the membrane is formed by partially etching a mask material including, for example, a silicon wafer from the back side of the mask, and a portion of the mask blank that is not etched serves as a support portion of the membrane.
- a stencil mask The one in which a transfer pattern is formed by providing holes in the membrane itself is called a stencil mask (see, for example, H. C. Pfeiffer, Jpn. J. Appl. Phys. 34, 6658 (1995)).
- a transfer pattern is formed by processing a scatterer such as a metal thin film laminated on a membrane are used as a scattering membrane mask (eg, L. R Harriott. J. Vac. Sci. 3 ⁇ 4clmol. B 15, 2130 (1997) See).
- the transfer-type lithography uses a method in which the charged particle beam transmitted through the mask is reduced and projected by an electron / ion optics system (SCALPEL from Lucent Technologies, PREVAIL from IBM, EB stepper from Nikon, lithography from ion beam, etc.) ) And a method of transferring onto a wafer placed directly under the mask without using an electron / ion optical system (Ripple, LEEPL by Tokyo Seimitsu, etc.).
- LE Masks used for EPL are disclosed in, for example, JP-A-2002-231599, JP-A-2002-252157, JP-A-2002-270496, and JP-A-2002-343710.
- SCALPEL is an abbreviation for scattering with angular limitation in projection electron-beam lithograph
- PREVAIL is an abbreviation for projection exposure with variable axis immersion lenses
- LEEPL is an abbreviation for low-energy e-beam proximity lithography.
- a typical manufacturing flow of a stencil mask and a scattering membrane mask will be described.
- a silicon oxide film 102 is formed on the back surface of an SOI wafer 101.
- the SOI (silicon on insulator or semiconductor on insulator) wafer 101 has a silicon layer 105 on a silicon wafer 103 via a silicon oxide film (buried oxide film) 104.
- the silicon oxide film 102 is etched.
- etching is performed on the silicon wafer 103 from the back side of the SOI wafer 101. This etching is performed using the silicon oxide layer 102 as a mask until the silicon oxide layer 104 is reached. Since the etching rates of silicon and silicon oxide differ by several orders of magnitude or more, the silicon wafer 103 is etched selectively with respect to the silicon oxide film 104 and the silicon oxide film 102. Etching stops at the silicon oxide film 104.
- a portion of the silicon oxide film 104 exposed by etching of the silicon wafer 103 is removed.
- a membrane 106 made of silicon is formed.
- the silicon wafer 103 which separates the membrane 106, becomes a beam 107 and supports the membrane 106.
- the silicon oxide film 104 is removed by, for example, wet etching using hydrofluoric acid. Ma
- the silicon oxide film 102 is also removed by this etching.
- the membrane 106 and the beam 107 are not formed near the edge of the SOI wafer 101, and the silicon wafer remaining in this portion is used as a mask support frame.
- a resist 108 is applied on the silicon layer 105 including the membrane 106.
- a mask pattern is drawn on the resist 108, and the resist 108 is developed.
- An electron beam writer is used to draw the mask pattern.
- the silicon layer 105 is etched using the resist 108 as a mask to form a hole 109 in a transfer pattern. Thereafter, by removing the resist 108, a stencil mask 110 is formed.
- the charged particle spring is irradiated from the back side (beam 107 side) of the stencil mask 110, and the pattern is transferred to the wafer by the charged particle beam passing through the hole 109.
- the membrane 106 and the wafer are arranged close to each other.
- silicon nitride films 112a and 112b are formed on both sides of a silicon wafer 111, for example, by chemical vapor deposition (CVD). Chemical vapor deposition).
- the silicon nitride film 112a on the mask front side becomes a membrane material, and the silicon nitride layer 112b on the mask back side becomes an etching mask for the silicon wafer 111.
- a tungsten layer 114 is formed on the silicon nitride film 112a via, for example, a chromium layer 113.
- the chromium layer 113 becomes an etching stopper layer when etching the tungsten layer 114, and the tungsten layer 114 becomes a scatterer of the charged particle beam.
- the silicon nitride film 112b on the back side of the mask is etched to remove the silicon nitride film 112b in the membrane formation region.
- a resist 115 is applied on the tungsten layer 114.
- silicon nitride Etching is performed on Ueno, 1 1 1 1 to form beams 1 16.
- a mask pattern is drawn on the resist 115, and the resist 115 is developed. An electronic di-drawing machine is used for drawing the mask pattern.
- the tungsten layer 114 is etched using the resist 115 as a mask, and the resist 115 is removed. Further, by etching the chromium layer 113 using the tungsten layer 114 as a mask, a transfer pattern is formed on the membrane 117 made of the silicon nitride film 112a, and the scattering membrane mask 118 is formed. Is formed.
- the formed scattering non-prene mask 1 18 is irradiated with a charged particle beam from the back side (beam 1 16 side) and passes through the membrane 1 17 except for the scatterer (tungsten layer 114).
- the pattern is transferred to the wafer by the charged particle beam.
- One of these conditions is to properly control the internal stress of the membrane. If the internal stress of the membrane is not properly controlled, the membrane will bow, causing pattern displacement and distortion. In the case of a stencil mask, since the internal stress is zero at the holes, stress concentration may occur in a part of the membrane depending on the pattern, and the membrane may be damaged.
- Another condition is to perform highly perpendicular and accurate etching when forming a pattern on a mask. If the wall of the scatterer of the hole-scattering membrane mask of the stencil mask is not vertical, electron beams used for exposure scatter on the wall. If the wall surface is not machined vertically, the thickness of the mask will not be uniform near the wall surface, and there is a possibility that an electron beam or the like will pass through portions other than the holes. Therefore, the pattern is not transferred accurately. For the same reason, it is necessary to improve the line width uniformity and in-plane uniformity of the etching.
- Another condition is to perform accurate and quick defect inspection. It is also necessary to correct defects detected by the defect inspection accurately using, for example, a focused ion beam (FIB).
- FIB focused ion beam
- Still another condition is to prevent foreign matter from adhering to the mask.
- the mask is cleaned several times during the manufacturing process and before use, and it is necessary to clean the mask without breaking the fine pattern of the mask during these cleaning steps. In addition to cleaning the mask, it is also necessary to control foreign matter in the exposure apparatus and detect the accumulation of contaminants due to exposure.
- the present invention has been made in view of the above-described problems.Therefore, the present invention has made it possible to perform a destructive inspection without producing an inspection mask and to more accurately perform nondestructive 1 ⁇ . And a method of inspecting the same. Another object of the present invention is to provide a method of manufacturing a semiconductor device capable of performing a mask inspection such as a destructive inspection using an exposure mask and reducing the number of masks to be manufactured.
- a mask according to the present invention includes an exposure thin film having a predetermined pattern of a transparent portion and a non-transparent portion of an exposure beam, and the exposure thin film formed around the thin film for exposure.
- a thin film for inspection having a thickness J3 supporting a thin film, and a transmission portion and a non-transmission portion of the exposure beam, which are formed in a part of the thick film portion so as to be separated from the exposure thin film.
- the thin film for exposure has the same thickness and material as the thin film for exposure, and has a thin film for grading.
- the non-transmitting portion is a thin film, and the transmitting portion is a hole formed in the thin film.
- the transmitting portion is a thin film, and the non-transmitting portion is an exposure beam scatterer formed on the thin film.
- the inspection thin film may have a larger area and a larger deflection than the exposure thin film.
- the inspection thin film may have the transmission portions having different line widths.
- the inspection thin film may have portions where the densities of the transmission portions are different from each other.
- the difficult thin film may include a second fragile portion having a higher pattern damage probability than the first fragile portion having the highest pattern damage probability in the exposure thin film.
- a mask inspection method comprises: an exposure thin film having a predetermined pattern of a transparent portion and a non-transmissive portion of an exposure beam; A method for inspecting a mask having a thick film portion supporting the thin film for exposure, formed on the mask, comprising: a transmitting portion and a non-transmitting portion for a charged particle beam; A thin film for 1 ⁇ formed separately from the thin film for exposure, preferably a step of screwing the thin film for inspection having the same thickness and material as the thin film for exposure, and a result of the thin film for inspection Estimating the state of the exposure thin film.
- the word “encompass” in the inspection thin film may be a destructive inspection.
- the inspection on the inspection thin film includes measurement of internal stress by a bulge method.
- the transmission portion is a hole formed in the same etching step in the exposure thin film and the inspection thin film, and the step of performing the difficulty includes forming a part of the non-transmission portion in the inspection thin film.
- the method includes a step of irradiating the focused ion beam to cut the irradiated portion of the focused ion beam, and a step of observing the cut surface with an electron microscope and so-called facing the etching cross-sectional shape.
- the transmitting portions having different line widths and / or intervals are formed on the thin film for heat radiation, and the line width uniformity of the etching is further studied.
- the bell thin film is formed in a plurality of different places, and the in-plane uniformity of the etching is further examined.
- the transmission section is a hole formed in the same etching step in the exposure thin film and the inspection thin film, and the transmission section having a different line width and / or interval is formed in the thin film for inspection.
- the process of determining the line width conversion and corner rounding when comparing the actually formed holes with the design data of the inspection thin film, and the line width conversion and corner rounding determined for the inspection thin film are performed.
- the step of performing difficulties in the thin film for inspection is most performed in the thin film for exposure.
- the probability of damage to the sun is the highest or more than the density of the transparent portion in the portion, and the presence or absence of destruction of the pattern in the portion where the transparent portion is formed in the bell thin film.
- the transmitting portions having different line widths and / or intervals are formed in the thin film for inspection, and the presence or absence of a change in the pattern after cleaning or the foreign matter remaining on the mask after cleaning is determined by the following method. Confirm in the thin film for use.
- the transmission portions having different line widths and / or intervals are formed in the thin film for exposure, and contaminants are deposited on the thin film for exposure during exposure, so that the line width of the anode fluctuates. The effect is confirmed in the test thin film.
- a method of manufacturing a semiconductor device comprises: a thin film for exposure having a predetermined pattern of a transparent portion and a non-transparent portion of an exposure beam; An inspection thin film having a thick film portion for supporting the exposure thin film, and a transmission portion and a non-transmission portion of the exposure beam formed on a part of the thick film portion so as to be separated from the exposure thin film.
- a lithographic process is performed using the exposure thin film of the mask having the exposure thin film and the same thickness and material as the exposure thin film.
- the mask of the present invention in which the state of the thin film for exposure can be accurately grasped by the thin film for inspection, is used for lithography.
- T AT One Around Time
- costs are reduced.
- FIGS. 1A to 1F are cross-sectional views illustrating manufacturing steps of a method for manufacturing a stencil mask.
- 2A to 2F are cross-sectional views illustrating manufacturing steps of a method for manufacturing a scattering membrane mask.
- FIG. 3 is a plan view of a conventional mask.
- FIG. 4 is a plan view of the mask of the present invention.
- FIG. 5 is a schematic view of a membrane internal stress measuring apparatus used in the mask inspection method of the present invention.
- 6A and 6B show examples of patterns formed on the inspection membrane of the mask of the present invention.
- FIG. 7 is a perspective view showing a cross-sectional shape of the mask.
- FIG. 8A shows an example of pattern design data
- FIG. 8B shows an example of a pattern actually obtained from the design data of FIG. 8A.
- FIG. 9 is an example of a pattern formed on the inspection membrane of the mask of the present invention, and shows a pattern that can be used for adjusting the optical axis of the focused ion beam.
- FIG. 1OA and FIG. 1OB are diagrams showing examples of positions where a pattern that is vulnerable to impact is arranged in the mask for detecting a mask of the present invention.
- FIG. 11 is a view showing the pattern damage probability of the exposure membrane and the inspection membrane of the mask of the present invention.
- FIG. 12 is a diagram showing an example of the workflow of the method for manufacturing a semiconductor device according to the present invention.
- BEST MODE FOR CARRYING OUT THE INVENTION embodiments of a mask, a method for inspecting the mask, and a method for manufacturing a semiconductor device according to the present invention will be described with reference to the drawings.
- FIG. 4 is a plan view showing an example of the stencil mask of the present embodiment.
- the thin film for exposure (exposure membrane) divided by the beam 1 is arranged at the center of the silicon wafer 3 (support frame), which is a thick film part.
- Thick beam l a differs from beam 1 only in width, and has the same cross-sectional structure as beam 1.
- the stencil mask of this embodiment has a small section inspection thin film (inspection membrane) 4 in an area that is not used for actual exposure (an area that is not irradiated with a charged particle beam during exposure).
- the inspection membrane 4 is formed in the same process as the membrane 2 used for actual exposure.
- holes are formed as an inspection pattern in the same process as forming holes in the membrane 2 in a predetermined pattern.
- the beam 5 that divides the inspection membrane 4 has the same cross-sectional structure as the beam 1 that divides the exposure membrane 2.
- the present embodiment relates to a method for monitoring the internal stress of a membrane using the mask of the present invention.
- the methods for measuring the internal stress of the membrane constituting the stencil mask include (1) a method of observing the deflection of the membrane and calculating the internal stress based on the radius, and (2) a direct measurement of the internal stress. There are two ways to do this.
- the membrane will bend and the positional accuracy of the pattern will be reduced.
- a proximity exposure method such as LEEPL, when the membrane is greatly bent, the membrane may come into contact with the wafer and the mask may be destroyed.
- the amount of deflection of the membrane is actually measured using the inspection membrane 4 shown in FIG. 4 (method (1) above). This measurement was performed at the time of mask blanks completion (after removing the silicon wafer and forming the membrane and beam, but before forming the holes in the membrane, see Figure 1C). Judgment as to whether to proceed to the process If this is the case, mask blanks with insufficient adjustment of the internal stress can be eliminated.
- a height measuring device using laser light can be used for measuring the amount of deflection of the inspection membrane 4. Since the amount of deflection of the membrane can be measured even in non-broken soil, there is little advantage in providing an inspection membrane when compared to an inspection that requires a destructive inspection. However, for example, an inspection membrane with a larger area than the actual exposure membrane 2
- an alignment mark may be provided at the center of the membrane so that the radius of the center of the membrane can be accurately measured.
- the amount of radius of the membrane is within the allowable range when the mask blank is completed, if a hole is formed in the membrane in a subsequent step, the amount of deflection of the membrane may increase. Therefore, it is desirable to measure the amount of radius using the inspection membrane 4 not only when the mask blanks are completed but also immediately before introducing the mask into the exposure apparatus.
- the mask passes through a gap sensor, the gap sensor measures the distance between the mask and the wafer, and then the mask is placed immediately below the electron beam column. Since the mask passes through the gap sensor from one end, the inspection membrane provided near the outer periphery of the mask 4 force If the mask passes through the gap sensor before the actual exposure membrane 2, the actual exposure The danger of contact between the wafer and the membrane 2 can be detected and avoided.
- the mask may be rejected or the mask transported out of the exposure equipment may be subjected to the stress of the membrane again. Make adjustments to reduce the amount of deflection.
- the exposure accuracy is within the allowable range, change the setting of the exposure apparatus so as to increase the distance between the mask and the wafer, and then re-install the mask directly below the electron beam tube.
- the internal stress is determined from the relationship between the load on the membrane and the amount of deformation of the membrane by forcibly deforming the membrane using (see Masayoshi Esashi et al., “Micro-Massive Jung and Micro-mouth Mechatronics”, published by Baifukan).
- the membrane When the membrane is forcibly deformed, the membrane may be damaged or the pattern may be irreversibly displaced. Therefore, in the past, such a measurement was not performed with an exposure mask, and the internal stress was measured with a dummy mask manufactured under the same conditions as the exposure mask.
- the internal stress was not measured in the actual exposure mask, and the dummy mask--a plurality of samples with different internal stresses--was manufactured, which increased the mask manufacturing cost and TAT. Was. Furthermore, depending on the process stability such as ion implantation for adjusting the stress, the desired stress cannot be adjusted, and the yield of the mask may be reduced.
- FIG. 5 shows a schematic diagram of the bulge method.
- a method for measuring the internal stress of a thin film by the bulge method is disclosed in Japanese Patent Application Laid-Open No. Hei 11-237430 / Japanese Patent Application Laid-Open No. 2000-3296969.
- the mask 11 is fixed to a hollow sample holder 12.
- the inside of the sample holder 12 is evacuated by a vacuum pump 13.
- the degree of vacuum in the sample holder 12 is monitored by the pressure sensor 14, and the desired degree of vacuum is controlled by adjusting the valve 15.
- the deformation of the membrane 16 is measured by the number of light interference fringes generated at the gap between the optical glass 17 and the membrane 16.
- a light source For example, a He to Ne laser 18 is used, and laser light is introduced into the microscope 20 by a single mode optical fiber 19.
- the laser light is reflected by the half mirror 21 in the microscope 20, and the laser light is applied to the optical glass 17 and the membrane 16.
- the light interference fringes are imaged by the CCD camera 22 and sent to the TV monitor 23 and the computer 24.
- the computer 24 controls the X-Y monitor 25 at the laser irradiation position, the pressure sensor 14, the vanoleb 15, and the vacuum pump 13.
- a method using a vacuum pump is generally simple. By directly measuring the internal stress of the membrane using the above-mentioned apparatus and appropriately controlling the internal stress, it is possible to prevent the pattern position from being shifted due to the bending of the membrane and to expose the pattern with high precision.
- the present embodiment relates to an inspection method of a pattern cross-sectional shape using a mask of the present invention.
- a pattern suitable for observing the cross-sectional shape is arranged on the inspection membrane 4 of the stencil mask shown in FIG. Figure 6 shows an example of such a pattern.
- FIG. 6A is an enlarged view of the inspection membrane 4 of FIG. 4, and FIG. 6B is an enlarged view of a part of the inspection membrane 4 of FIG. 6A.
- a line-and-space pattern 6 having a line width of 200 nm and a pitch of 400 nm is formed, for example, in an area of 1 ⁇ m square as an observation pattern of a cross-sectional shape.
- the step of forming holes in the inspection membrane 4 in the line and space pattern 6 is the same as the step of forming holes in the exposure membrane 2 in a predetermined pattern.
- a part of the inspection membrane 4 is irradiated with FIB to cut the pattern 6.
- FIB gallium ion beam
- a stencil mask is mounted on a stage having a tilt mechanism, and the cross section of the membrane cut by the FIB is observed with a scanning electron microscope (SEM). From the SEM image obtained at this time, the taper angle 0 of the pattern shown in FIG. 7 can be obtained.
- the process from cutting of the pattern by FI ⁇ irradiation to observation of the cut surface should be performed by one device using, for example, SM 1-980 (manufactured by Seiko Instruments Inc.). Is also possible. Such an inspection process is a destructive inspection and cannot be performed with an exposure membrane.
- the taper angle of the pattern can be measured with high accuracy without producing a dummy mask. Therefore, it is possible to expose the pattern with high precision. Further, the cost for producing the dummy mask does not increase.
- the present embodiment relates to a method for inspecting line width uniformity and in-plane uniformity using the mask of the present invention.
- the line width uniformity and the in-plane uniformity of the pattern formed by the etching process vary depending on the line width and density of the pattern.
- the phenomenon in which the etching rate is dependent on the etching area, and the etching rate decreases as the etching area increases, is called a mouthing effect.
- the phenomenon that the etching rate decreases as the line width (hole diameter) of the pattern is reduced, and the phenomenon that the etching rate is not uniform when patterns with the same line width exist at different densities are considered. , Called the microloading effect.
- the stencil mask membrane and the charged particle beam scatterer of the scattering membrane mask are processed by etching using a resist as a mask. Therefore, in addition to the line width variation caused by the above-described etching process, there is also the line width variation caused by the resist 1 and the forming process.
- the resist line width fluctuates according to the pattern spacing, and the amount of change in line width and in-plane uniformity are also affected by the resist line width.
- the pattern edge roughness is not uniform even on a membrane whose pattern edge roughness is inherited by etching.
- SEM observation is performed as in the second embodiment. Lines and spaces having different line widths and pattern intervals are formed on the inspection membrane 4 for the mask of the present invention. If the resist line width before etching and the pattern line width after etching are measured by SEM or the like, the line width uniformity and in-plane uniformity can be inspected.
- the inspection membrane 4 is provided at a plurality of locations other than the exposure membrane 2 and the same inspection pattern is formed on the plurality of inspection membranes 4, the CD (critical dimension) distribution in the mask surface can be monitored. it can.
- the present embodiment relates to creation of a reference image when performing a defect inspection using the mask of the present invention.
- mask defect inspection There are two types of mask defect inspection: a method that compares adjacent chips (die-to-die method) and a method that compares a mask pattern with design data (die-to-database method or DB method).
- the die-to-die method cannot detect a defect with the same shape on the chip to be compared, but the die-to-database method does not cause such a problem. Inspection is often performed using the database method.
- a reference image is created from the pattern on the mask using the optical system of the inspection device.
- reference images are created from the design data, and these reference images are compared to detect defects.
- a pattern is formed through formation of a resist pattern by a drawing apparatus, etching, and removal of the resist, so that a pattern that completely matches the design data cannot be obtained. Specifically, the width of the fountain in the pattern fluctuates, and corner rounding occurs.
- FIG. 8 shows an example of line width fluctuation and corner rounding after pattern formation.
- Fig. 8A shows the design data, which is a line-and-space pattern with a width L.
- FIG. 8A is an example of a pattern formed on a mask based on the design data of FIG.
- the line width in Fig. 8B is L soil ⁇ L, and the corner of the pattern is a curve of radius of curvature R.
- a mask image ⁇ obtained by the optical system of the inspection apparatus, a correction of line width variation and corner rounding are added, and a reference image close to the reference image of the design data is created.
- non-destructive measurement of line width variation and corner rounding may be performed.
- Setting parameter values for creating reference images based on line width fluctuations and corner rounding in the inspection membrane not only eliminates the cost and labor of creating dummy masks, but also Since parameter values of a membrane manufactured by the same process as that of an exposure membrane can be used, parameter values can be optimized with high accuracy. Therefore, comparison of the reference images can be performed in a shorter time, and defects can be detected with high accuracy.
- the present embodiment is an example in which the mask of the present invention is used for defect correction using FI.
- a pattern as shown in FIG. 9 is arranged on the inspection membrane 4 of the stencil mask shown in FIG.
- a square pattern with a side of 10 ⁇ Are arranged in a 3 ⁇ 3 matrix at intervals of 10 ⁇ m.
- the pattern of the membrane for inspection 4 is formed in the same process as the pattern of the membrane 2 for exposure.
- a black defect is a defect in which a membrane (a charged particle beam scatterer in the case of a scattering membrane mask) remains in the pattern portion that should become a hole. Black defects occur when foreign matter adheres to the resist pattern and the pattern to be etched remains without being etched.
- white defects are defects where holes are formed in addition to the pattern. White defects are caused by the fact that the resist pattern is chipped or the remaining pattern is erroneously etched.
- black defects are corrected by processing (milling) using a gallium ion beam or gas-assisted etching (GAE), which jets gas onto the sample and performs efficient etching.
- White defects are corrected by irradiating a gallium ion beam in an organic gas atmosphere such as pyrene to form a carbon thin film at the irradiation position.
- the optical axis of the ion beam is adjusted, specifically, focusing and astigmatism are adjusted. This optical axis adjustment is performed by detecting secondary ions (or secondary electrons) emitted when the mask is irradiated with the ion beam.
- the stencil mask membrane material used for electron beam lithography is silicon, and a residual metal such as gallium is present, a contact potential difference may occur due to contact between different kinds of substances.
- the position of the subsequently incident electrons may shift (charge-up). Since the contact potential difference due to the remaining gallium causes charge-up, the irradiation amount of the gallium ion beam on the exposure membrane can be minimized.
- the optical axis is adjusted using a pattern as shown in FIG. 9 formed on the inspection membrane. Gallium in the pattern shown in Figure 9 Irradiate the ion beam and make adjustments so that the edges of the resulting secondary ion image are clear. After that, the mask stage is moved, and the gallium ion beam is irradiated to the defect to correct it.
- Embodiment 6 As described above, by adjusting the optical axis of the ion beam with the inspection membrane provided separately from the exposure membrane, it is possible to reduce the amount of gallium remaining on the exposure membrane. This prevents a change in the mask when the mask is used for exposure, and allows the mask pattern to be accurately transferred onto the wafer.
- the present embodiment relates to a method for monitoring mask damage due to repeated use, transportation, or cleaning.
- a 1: 1 stencil mask such as that used in LEEPL
- a fine pattern is formed at an equal magnification on an extremely thin membrane, so that the pattern is easily damaged by physical impact.
- Pattern damage due to impact during the mask manufacturing process is detected by defect inspection immediately after completion of the mask.However, during the transportation of the shipped mask, during handling to use the mask with the exposure equipment, or during exposure for exposure. It is necessary to check the pattern for damage caused by the impact of cleaning the mask.
- the surface of the membrane In the case of a 1: 1 stencil mask having an extremely thin membrane, the surface of the membrane is likely to be significantly roughened by a chemical solution during the mask cleaning. Roughness of the membrane surface causes fluctuations in pattern dimensions and pattern rupture.
- the mask whose pattern has been destroyed is unusable and is discarded. If damage to the pattern is tolerable, the mask is used repeatedly for exposure. Therefore, it is necessary to accurately determine the degree of pattern damage. If the mask is used repeatedly, the mask will be cleaned if necessary.
- the pellicle which is the protective film.
- LEEPL low-acceleration electrons
- a finer pattern is arranged on the stencil mask inspection membrane 4 of FIG. 4 in which the line width and / or interval among the actual device patterns is equal to or greater than the finest pattern. .
- the force with the smallest line width and the pattern density (density of the hole portion) or both of them are the first vulnerable portion in the exposure membrane 2 in FIG. Form a second vulnerable area on membrane 4 that is more fragile than the first vulnerable area.
- a fine line-and-space pattern or a cantilever-shaped pattern called a leaf pattern which is easily broken, is arranged.
- Such patterns have poor mechanical strength and are susceptible to damage, making them suitable for monitoring the accumulation of damage due to transport, repeated use, or cleaning.
- Pattern damage can be observed using, for example, an SEM, but it is also easier to visually determine the timing of mask disposal.
- the entire inspection membrane 4 is defined as a second vulnerable portion.
- a second fragile portion is formed at a portion of the inspection non-plane 4 along the boundary with the silicon wafer 3.
- the inspection membrane 4 falls out in a size close to its size.
- the size of the inspection membrane 4 is, for example, about 1 mm square, it is sufficiently possible to visually check the detachment of the inspection membrane 4. Therefore, it is possible to reliably eliminate a mask having a possibility of pattern rupture in the exposure membrane 2 without performing inspection using an apparatus such as an SEM.
- the second vulnerable part is not necessarily the whole of the inspection membrane 4 or the boundary of the inspection membrane 4. It is not necessary to form in the vicinity.
- the size of the second vulnerable part combined with the part surrounded by the second vulnerable part should be large enough to be visually confirmed.
- the mask pattern damage probability B of the second fragile portion of the inspection membrane 4 is higher than the mask pattern damage probability B of the first fragile portion of the exposure membrane 2
- the risk of pattern damage in the exposure membrane 2 can be predicted from the damage state of the pattern in the inspection membrane 4. For example, in the case of the impact strength X shown in Fig. 11, pattern damage is detected in the inspection membrane 4, but it is assumed that pattern damage does not occur in the exposure membrane 4, so that there is a margin for pattern damage. The mask can be discarded.
- the margin is increased by increasing the difference between the mask pattern damage probability A and the mask pattern damage probability B, the number of times the mask can be used repeatedly for exposure decreases. Therefore, it is desirable to reduce the margin as far as the mask in which the pattern is destroyed can be eliminated.
- the correlation between the strength of the impact and the probability of damage to the mask pattern as shown in Fig. 11 is checked in advance for a plurality of types of patterns.
- the exposure membrane 2 can be used, exposure can be performed using a mask. According to the present embodiment, it is possible to grasp the degree of damage to the pattern due to an impact during transportation or cleaning, and to accurately determine the timing of mask disposal.
- the present embodiment relates to a method for monitoring contamination of a mask. Since a stencil mask for low-acceleration electron beam lithography cannot be provided with a protective film such as a pellicle, foreign matter that may interfere with exposure may adhere to the mask due to handling when using the mask. . However, it is not practical to perform a detailed foreign substance inspection on the entire area used for exposure, because it takes an enormous amount of time.
- the contamination state of the exposure membrane 2 is estimated based on the result.
- the inspection membrane 4 is formed with a line and space pattern with different line widths and intervals. If the inspection membrane 4 is inspected in detail using a SEM type defect inspection device or the like, the contamination of the mask can be inspected in a short time. By monitoring the increase or movement of foreign matter before and after handling when using a mask with the inspection membrane 4, it is possible to estimate the presence or absence of foreign matter in the exposure membrane 2 that affects exposure.
- the present embodiment relates to a method for monitoring a line width variation due to a contaminant deposition on a mask. Since a stencil mask for low-acceleration electron beam lithography cannot be provided with a protective JI like a pellicle, when the mask is irradiated with an electron beam during exposure, the gas generated in the exposure system gradually increases the gas. Contaminants deposit on the mask. When such contaminants accumulate on the mask pattern sidewalls, the pattern line width becomes thinner and the pattern edge roughness deteriorates. Therefore, the transfer of the pattern is affected. Contaminants deposited at locations away from the ⁇ and ° turns do not directly affect the line width of the mask pattern, but can cause charge-up during exposure and reduce the line width of the transferred pattern. Fluctuate. For these reasons, it is important to monitor the contaminants deposited on the mask and estimate the effect on exposure.
- line-and-space patterns having different line widths and intervals are formed on the inspection membrane 4 of the stencil mask shown in FIG.
- the accumulation of contaminants on the mask can be measured by directly measuring the line width of the pattern of the inspection membrane 4 by SEM observation, or by transferring the pattern of the inspection membrane 4 onto the wafer by exposure.
- the measured line width may be measured, and either may be used.
- the pattern of the inspection membrane 4 is exposed to a portion that does not affect the electrical characteristics of the device.
- the timing of mask cleaning or disposal can be determined. Also, before and after cleaning the mask, The effectiveness of cleaning can be monitored by monitoring the contamination status of the mask by the method.
- FIG. 12 shows an example of the workflow of the semiconductor device manufacturing method according to the present embodiment.
- Step 1 a resist is applied to the substrate.
- step 2 a mask is placed on the substrate.
- the mask includes an exposure thin film having a transmission portion and a non-transmission portion of the exposure beam, a thick portion formed around the exposure thin film and supporting the exposure thin film, and a mask for the exposure beam.
- a mask of the present invention having a transmitting portion and a non-transmitting portion, and having a thin film for inspection and a thin film for inspection having the same thickness and material as the thin film for exposure is used.
- step 3 the exposure thin film of the mask is exposed by the exposure beam.
- step 4 the resist on the substrate is developed.
- step 5 for example, an ion implantation step, a dry etching step, and the like are performed as a later step to manufacture a semiconductor device.
- the mask of the present invention since the state of the thin film for exposure can be accurately grasped by the thin film for inspection, the yield in mask manufacturing is high, and the mask delivery time is shortened. Therefore, according to the method of manufacturing a semiconductor device of the present invention using the mask of the present invention, a reduction in TAT in mask manufacturing can be expected. In addition, it is possible to perform various inspections including destructive inspection using a mask used for exposure without separately manufacturing an inspection mask for mask inspection, thereby reducing the manufacturing cost of a semiconductor device. .
- Embodiments of the mask, the inspection method thereof, and the method of manufacturing a semiconductor device of the present invention are not limited to the above description.
- an example of a stencil mask is shown.
- an inspection thin film may be provided in a region not used for exposure of the scattering membrane mask to perform various inspections.
- the mask of the present invention and the inspection method thereof are not limited to a stencil mask for electron beam lithography, but may be a mask for ion beam lithography or another exposure beam such as X-ray or EUV (extreme ultraviolet) light.
- the present invention can be applied to a stencil mask or a membrane mask for lithography using.
- the mass of the present invention The mask and its inspection methods can be applied to stencil masks used in other processes such as ion implantation.
- various changes can be made without departing from the gist of the present invention.
- the mask of this invention its inspection method, and the manufacturing method of a semiconductor device, it is possible to more accurately perform a mask including a destructive inspection without manufacturing an inspection mask separately from an exposure mask. Become.
Landscapes
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Preparing Plates And Mask In Photomechanical Process (AREA)
- Electron Beam Exposure (AREA)
- Exposure And Positioning Against Photoresist Photosensitive Materials (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP03738542A EP1536283A4 (en) | 2002-06-28 | 2003-06-27 | MASK, INSPECTION METHOD, AND METHOD FOR PRODUCING SEMICONDUCTOR DEVICE |
US10/518,345 US20060008707A1 (en) | 2002-06-28 | 2003-06-27 | Mask and inspection method therefor and production method for semiconductor device |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2002-191099 | 2002-06-28 | ||
JP2002191099 | 2002-06-28 | ||
JP2003-129523 | 2003-05-07 | ||
JP2003129523A JP2004088072A (ja) | 2002-06-28 | 2003-05-07 | マスクおよびその検査方法 |
Publications (1)
Publication Number | Publication Date |
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WO2004003664A1 true WO2004003664A1 (ja) | 2004-01-08 |
Family
ID=30002324
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2003/008176 WO2004003664A1 (ja) | 2002-06-28 | 2003-06-27 | マスクおよびその検査方法並びに半導体装置の製造方法 |
Country Status (6)
Country | Link |
---|---|
US (1) | US20060008707A1 (ja) |
EP (1) | EP1536283A4 (ja) |
JP (1) | JP2004088072A (ja) |
KR (1) | KR20050027225A (ja) |
TW (1) | TWI227370B (ja) |
WO (1) | WO2004003664A1 (ja) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10839972B2 (en) | 2017-03-14 | 2020-11-17 | Joseph T. Young | High resolution X-Ray imaging system |
Families Citing this family (9)
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JP4657646B2 (ja) * | 2004-07-30 | 2011-03-23 | ソニー株式会社 | マスクパターン配置方法、マスク作製方法、半導体装置の製造方法、プログラム |
CN100595671C (zh) | 2004-11-08 | 2010-03-24 | Hoya株式会社 | 掩模坯件的制造方法 |
JP4529736B2 (ja) * | 2005-03-08 | 2010-08-25 | 凸版印刷株式会社 | レチクル |
US7259373B2 (en) * | 2005-07-08 | 2007-08-21 | Nexgensemi Holdings Corporation | Apparatus and method for controlled particle beam manufacturing |
WO2008140585A1 (en) | 2006-11-22 | 2008-11-20 | Nexgen Semi Holding, Inc. | Apparatus and method for conformal mask manufacturing |
US10991545B2 (en) | 2008-06-30 | 2021-04-27 | Nexgen Semi Holding, Inc. | Method and device for spatial charged particle bunching |
US10566169B1 (en) | 2008-06-30 | 2020-02-18 | Nexgen Semi Holding, Inc. | Method and device for spatial charged particle bunching |
US8479589B2 (en) * | 2008-07-23 | 2013-07-09 | University Of Kentucky Research Foundation | Method and apparatus for characterizing microscale formability of thin sheet materials |
JP7244067B2 (ja) * | 2019-03-25 | 2023-03-22 | 株式会社日立ハイテクサイエンス | マスク欠陥修正装置、及びマスク欠陥修正方法 |
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- 2003-06-27 TW TW092117690A patent/TWI227370B/zh not_active IP Right Cessation
- 2003-06-27 KR KR1020047021229A patent/KR20050027225A/ko not_active Application Discontinuation
- 2003-06-27 EP EP03738542A patent/EP1536283A4/en not_active Withdrawn
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Also Published As
Publication number | Publication date |
---|---|
EP1536283A1 (en) | 2005-06-01 |
TW200410046A (en) | 2004-06-16 |
US20060008707A1 (en) | 2006-01-12 |
EP1536283A4 (en) | 2008-05-07 |
TWI227370B (en) | 2005-02-01 |
KR20050027225A (ko) | 2005-03-18 |
JP2004088072A (ja) | 2004-03-18 |
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