KEYWORDS: Semiconducting wafers, Photomasks, Critical dimension metrology, Quartz, Pulsed laser operation, Signal attenuation, Beam controllers, Deep ultraviolet, Metrology, Process control
Requirements for control of critical dimension (CD) become more demanding as the integrated circuit (IC) feature size specifications become tighter and tighter. Critical dimension control, also known as CDC, is a well-known laser-based process in the IC industry that has proven to be robust, repeatable, and efficient in adjusting wafer CD uniformity (CDU) [Proc. SPIE6152, 615225 (2006)]. The process involves locally and selectively attenuating the deep ultraviolet light which goes through the photomask to the wafer. The input data for the CDC process in the wafer fab is typically taken from wafer CDU data, which is measured by metrology tools such as wafer-critical dimension—scanning electron microscopy (CD-SEM), wafer optical scatterometry, or wafer level CD (WLCD). The CD correction process uses the CDU data in order to create an attenuation correction contour, which is later applied by the in-situ ultrashort laser system of the CDC to locally change the transmission of the photomask. The ultrashort pulsed laser system creates small, partially scattered, Shade-In-Elements (also known as pixels) by focusing the laser beam inside the quartz bulk of the photomask. This results in the formation of a localized, intravolume, quartz modified area, which has a different refractive index than the quartz bulk itself. The CDC process flow for improving wafer CDU in a wafer fab with detailed explanations of the shading elements formation inside the quartz by the ultrashort pulsed laser is reviewed.
Laser breakdown in liquid induced by ultrafast high repetition rate laser pulses tightly focused close to a flat or curved
surface of a liquid-gas boundary is investigated. It is shown, that in case of focusing a laser beam close to the liquid - gas
boundary a low divergent jet appears consisting of liquid and bubbles of micron size and less. The direction of the jet
coincides with the perpendicular to the boundary surface, passing through the objective focal point. The length of the jet
depends on the kind of liquid, laser pulse parameters and the distance between the beam focus point and the liquid - gas
boundary and may reach several centimeters.
KEYWORDS: Photomasks, Signal attenuation, Semiconducting wafers, Birefringence, Polarization, Image processing, Critical dimension metrology, Chemical elements, Scanners, Process control
Mask and Wafer CD Uniformity (CDU) improvement by utilizing an ultrafast laser system for writing shading elements inside the bulk of Quartz (Qz) Photomasks has previously been shown to be an effective and practical application (1).
The CD Control ( CDC) Process is working in production environments for 90 and 65 nm design rule processes which utilize KrF and ArF scanners.
Advanced design rule nodes at 45 and 32 nm will utilize high and hyper NA immersion lithography, which require highly polarized light and immersion technology. Maintaining a high degree of polarization requires low birefringence (BF) of the optical path and specifically of the mask. Current mask blanks contribute between 5 to 20 nm of BF which is too high for polarized systems. This lead to the recent introduction of special low BF blanks which provide <1nm BF per mask.
The CDC Process which introduces an optical element inside the quartz (Qz) mask performs a local change of the bulk Qz morphology which causes a local change in refractive index of the Qz and may induce some local BF. The induced BF, if too high, may potentially cause depolarization of the highly polarized light of hyper NA scanners. Depolarizing the light by a high degree has the potential to degrade the image contrast in the litho process
The current study examined the effect of the CDC Process on the mask BF at 193 nm by writing controlled attenuation shading elements inside special low BF Qz blanks and measuring the BF induced by the CDC Process.
Results: It was found that BF induced by the CDC Process is so small that its effect on loss of CDU is negligible compared to the gain in CDU. This will allow mask and IC manufactures to take advantage of Pixer's CDC Process in hyper NA litho processes at 45 and 32 nm nodes.
Intra-field CD variation is, besides OPC errors, a main contributor to the total CD variation budget in IC manufacturing. It is caused mainly by mask CD errors. In advanced memory device manufacturing the minimum features are close to the resolution limit resulting in large mask error enhancement factors hence large intra-field CD variations. Consequently tight CD Control (CDC) of the mask features is required, which results in increasing significantly the cost of mask and hence the litho process costs. Alternatively there is a search for such techniques (1) which will allow improving the intrafield CD control for a given moderate mask and scanner imaging performance. Currently a new technique (2) has been proposed which is based on correcting the printed CD by applying shading elements generated in the substrate bulk of the mask by ultrashort pulsed laser exposure. The blank transmittance across a feature is controlled by changing the density of light scattering pixels. The technique has been demonstrated to be very successful in correcting intra-field CD variations caused by the mask and the projection system (2). A key application criterion of this technique in device
manufacturing is the stability of the absorbing pixels against DUV light irradiation being applied during mask projection in scanners.
This paper describes the procedures and results of such an investigation. To do it with acceptable effort a special experimental setup has been chosen allowing an evaluation within reasonable time. A 193nm excimer laser with pulse duration of 25 ns has been used for blank irradiation. Accumulated dose equivalent to 100,000 300 mm wafer exposures has been applied to Half Tone PSM mask areas with and without CDC shadowing elements. This allows the
discrimination of effects appearing in treated and untreated glass regions. Several intensities have been investigated to define an acceptable threshold intensity to avoid glass compaction or generation of color centers in the glass. The impact of the irradiation on the mask transmittance of both areas has been studied by measurements of the printed CD on wafer using a wafer scanner before and after DUV irradiation.
As pattern feature sizes on the wafer become smaller and smaller, requirements for CD variation control has become a critical issue. In order to correct CD uniformity on the wafer, the DUV light transmission distribution of the photomask was altered using an ultra-fast pulsed laser technology. By creating a small scattering pixel inside the quartz body of the mask, a multitude of such points creates Shading Elements inside the quartz according to a predetermined CD variations distribution map. These Shading Elements reduce the dose of scanner's laser illumination onto the wafer per a local area. Thus by changing the local light intensity, inside the exposure field, to a required level during the photolithographic process the wafer CD is changed locally inside the field. This complete process of writing a multitude of Shading Elements inside the mask in order to control the light transmission and hence wafer level CD locally is called the CD Control (CDC) process.
We have evaluated the tool utilizing Ultra fast laser pulses (CDC 101) for local transmission and CD controllability on the wafer. We used Binary and Att-PSM test masks and three kinds of test patterns to confirm the sensitivity of transmission and CD change by the attenuation levels of Shading Elements which is sequentially changed from 0% to 10%. We will compare the AIMS results to printed CD on wafer or simulation results, so that we can correlate the transmission change and CD change by the attenuation levels. This paper also reports the CD uniformity correction performances by using attenuation mapping method on Binary mask. We also cover how Shading Elements affect the phase and transmission on the Att-PSM.
As IC feature sizes become smaller and smaller, requirements for Critical Dimension (CD) variations control have become a critical issue. A new process for the control and correction of intra-field CD variations (Critical Dimension Control or CDC) was applied and it's influence on defects detection and photo-masks inspection capabilities at different modes of inspection was investigated.
CD Control (CDC) of the photomask is a process in which Deep UV transmittance is selectively altered by patterns of small partially scattering shading elements (Shade in ElementTm) inside the quartz. The shading elements are formed by a process of shooting an ultrafast laser beam focused inside the mask substrate, resulting in localized intra-volume breakdown inside the quartz which creates local pixels of modified index of refraction (delta n). An array of such pixels with constant density constitutes one shading element. Process patterns are predetermined according to a CD variations map which may be supplied from wafer CD SEM, Optical CD or mask aerial imaging simulation tool (AIMS). Thus by changing local photomask transmission levels, it is possible to correct for the CD variations inside the field.
Attenuation level, or optical density of the shading elements depends on the laser pulse energy, distance between pixels, number of layers and the size of the shading element itself.
Since photomask transmittance is being changed, qualification of the impact of the transmittance changes on the defect detection and analysis capabilities are required. In this study, the principles of patterning of scattering elements inside transparent media by focusing of ultra-short laser pulses were introduced and explained. Analysis of the effects to both mask and wafer due to the CDC process was verified by full printing process applied to wafers, and by aerial imaging simulation tool. More tests for CDC required also tests by automatic reticle inspection tool to be production-worthy for the 65nm node and beyond.
The applicability of ultrafast laser 3D machining of transparent objects for photomask clear defects repair is investigated. The technology is based on patterning 3D shading elements inside quartz body of the photomask at the vicinity of clear defects in chrome layer, which effectively blocks the light for the duration of the photolithography process. Shading elements consist of an array of breakdown points in quartz, produced as a result of laser-induced breakdown and arranged in accordance with the size and location of the defects. Thresholds of bulk breakdown and chrome removal at laser irradiation from the back side of the photomask and their dependence on the pulse energy and height of focal point under chrome layer were obtained. Optical density of the shading element depends on the laser pulse energy, distance between breakdown points, the number of layers and the size of the shading element itself. To increase optical density multi layer shading elements were created. Ultrafast laser technology and a tool for photomask clear defects repair are described.
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