The abnormal growing defect (we called this defect 'scum haze defect') in the photomask which is generated during the wafer lithography process is very important issue on semiconductor industry. Because wafer yield loss could be caused by the mask CD variation and the transmittance loss due to the growing defects on the photomask, many studies have been done about the mechanism and the solution of the general type growing defects such as haze and Cr migration so far, However we still need to clarify some abnormal types of the growing defects such as scum haze defect. In this paper, we investigated the generation mechanism and prevention techniques of the scum haze defect on the attenuated phase shift mask. This defect composed of CrOx is caused by the increase of the accumulated exposure energy on photomask. This phenomenon is remarkably similar to the Cr migration on binary mask. But, the apparent difference is that this scum type defect is observed on the attenuated phase shift mask which mainly consists of MoSiON film, and it is difficult to control this defect because of its irregular generation characteristic. Additionally, this defect is not generally removed through the conventional wet cleaning process but it only could be removed by a kind of plasma treatment. In this study, the difference of generation mechanism between the scum haze defect and the general haze was discussed, and the optimal process for controlling scum haze defect in the mask manufacturing was described.
As the mask specifications become tighter for low k1 lithography, more aggressive repair accuracy is required below sub 20nm tech. node. To meet tight defect specifications, many maskshops select effective repair tools according to defect types. Normally, pattern defects are repaired by the e-beam repair tool and soft defects such as particles are repaired by the nanomachining tool. It is difficult for an e-beam repair tool to remove particle defects because it uses chemical reaction between gas and electron, and a nanomachining tool, which uses physical reaction between a nano-tip and defects, cannot be applied for repairing clear defects.
Generally, film deposition process is widely used for repairing clear defects. However, the deposited film has weak cleaning durability, so it is easily removed by accumulated cleaning process. Although the deposited film is strongly attached on MoSiN(or Qz) film, the adhesive strength between deposited Cr film and MoSiN(or Qz) film becomes weaker and weaker by the accumulated energy when masks are exposed in a scanner tool due to the different coefficient of thermal expansion of each materials. Therefore, whenever a re-pellicle process is needed to a mask, all deposited repair points have to be confirmed whether those deposition film are damaged or not. And if a deposition point is damaged, repair process is needed again. This process causes longer and more complex process.
In this paper, the basic theory and the principle are introduced to recover clear defects by using nanomachining tool, and the evaluated results are reviewed at dense line (L/S) patterns and contact hole (C/H) patterns. Also, the results using a nanomachining were compared with those using an e-beam repair tool, including the cleaning durability evaluated by the accumulated cleaning process. Besides, we discuss the phase shift issue and the solution about the image placement error caused by phase error.
As the pattern size became gradually smaller, the defect detectability of the photomask inspection tool was more improved. For these reasons, we have to repair various defects more precisely. By improving the mask yield through the repair process, we can reduce the cost of mask fabrication. In this study, we studied the defect called quartz damage which distorts the AIMSTM (Arial Image Measurement System) intensity of the repaired pattern and causes the scrap of the photomask. The quartz damage is generally observed when the abnormal defects like particles were repaired in the poor repairing condition. The quartz damage occasionally results in repair errors and affects the AIMS intensity. Currently there is no clear solution for recovering the quartz damage. As a result, it is very difficult to get the high quality photomask if the quartz damage is generated on the photomask. Therefore, it is important to find a method of recovering the quartz damage for producing the high quality photomask. In this paper, we demonstrated that the quartz damage can be recovered through the TEOS (Tetraethoxysilane) gas deposition. Also we investigated the effect on the recovery of the quartz damage of various parameters such as the type and the depth of the quartz damage as well as the repair conditions of the TEOS gas deposition.
As the number of masks per wafer product set is increasing and low k1 lithography requires tight mask
specifications, the patterning process below sub 20nm tech. node for critical layers will be much more expensive
compared with previous tech. generations. Besides, the improved resolution and the zero defect level are necessary to
meet tighter specifications on a mask and these resulted in the increased the blank mask price as well as the mask
fabrication cost.
Unfortunately, in spite of expensive price of blank masks, the certain number of defects on the blank mask is
transformed into the mask defects and its ratio is increased. But using high quality blank mask is not a good idea to
avoid defects on the blank mask because the price of a blank mask is proportional to specifications related to defect
level. Furthermore, particular defects generated from the specific process during manufacturing a blank mask are
detected as a smaller defect than real size by blank inspection tools because of its physical properties. As a result, it is
almost impossible to prevent defects caused by blank masks during the mask manufacturing.
In this paper, blank defect types which is evolved into mask defects and its unique characteristics are observed.
Also, the repair issues are reviewed such as the pattern damage according to the defect types and the repair solution is
suggested to satisfy the AIMS (Arial Image Measurement System) specification using a nanomachining tool.
The etch chambers has been cleaned by wet process and replaced with new parts to maintain etch chamber perfectly
clean. However, the wet cleaning process results in following issues. One of issues is that the critical dimension mean to
target (CD MTT) and phase-shift would be changed due to the variation of etch rate, which is generally caused by the
new parts and wet chamber cleaning process. Another issue is that the wet cleaning process takes long time to recover
the chamber condition. Moreover, the production will be stopped until recovering the chamber condition. Therefore,
the recovering time should be minimized to keep the high productivity of etch tool.
The change of chamber condition during the plasma seasoning can be monitored with the optical emission
spectroscopy (OES) system. The optical emission intensity represents the concentration of materials in the plasma and
the surface condition of chamber. The OES peak intensities were collected during the plasma seasoning, which was
applied to remove the moisture and residues. The correlation of the OES peak intensities and chamber condition was
verified by the CD and phase-shift difference between pre and post chamber cleaning. This methodology was applied to optimize the seasoning time, which occupies 80% of whole the chamber cleaning process time.
There has been a growing demand for more precise Mask CD MTT (Critical Dimension Mean to Target) control by
shrinking the semiconductor device. Generally, The CD MTT is determined by patterning process such as writing,
develop, and etch. But, additional CD MTT variation often occurs by cleaning process after patterning process. As a
result, it is important to preserve the CD MTT for minimizing CD variation by cleaning process. The cleaning process of
photomask is becoming more critical for 32nm node and below because the size of defect and SRAF pattern is in the
same range. In order to achieve high first cleaning pass yields, intensive cleaning method depending on media not
physical force is still essential to photomask manufacturing and these cleaning processes bring about considerable CD
MTT change. Therefore, it is necessary to increase the durability of MoSi material of attenuated HTPSM (Half Tone
Phase Shift Mask) by the new surface treatment method.
In this study, we presented the plasma etching technique for Cr strip etch in the 2nd process of the attenuated HTPSM for
minimizing CD variation by cleaning process. Diverse dry etching processes are investigated to improve the durability of
the MoSi patterns. In order to evaluate the surface modification of the MoSi film, surface compositions are analyzed by
XPS (X-ray Photoelectron Spectroscopy), TOF-SIMS (Time of Flight Secondary Ion Mass Spectrometry), and EELS
(Electron Energy Loss Spectroscopy). The variation of CD MTT and optical properties are also evaluated by CD SEM
and AIMS (Aerial Image Measurement System), respectively. The XPS analysis shows that sidewall passivation films
are formed during the main etch process and then modified at the over etch step and additional in-situ O2 plasma
treatment. The concentration of the MoO3 is increased when over etch step and in-situ O2 plasma treatment are added.
The difference of CD shift between initial measurement and 2nd measurement after cleaning process depends on plasma
etching conditions. Consequently, the increase in the peak intensity of MoO3 that is less soluble than that of MoO2 leads
to preserve CD by cleaning chemicals.
As technical advances continue, the pattern size of semiconductor circuit has been shrunk. So the field of the photomask needs the processing more strictly. It is critical to the photomask which contained considerably shrank circuit and ultra high density pattern for sub-20 nm tech device, although a small defect is negligible in the conventional process. Even if some defect can be repaired, it is not satisfied with a strict pattern specification. Stricter fabrication process and pattern specification increase the manufacture cost. Furthermore, EUV photomask manufacture cost is several times expensive than the conventional photomask. Therefore the effort to decrease defects is important for the photomask fabrication process. In addition, when defects are generated, it is obviously important that the repaired patterns have better pattern reliability. In this paper, we studied about advanced processes that control and remove hard defects minutely .on ArF attenuated phase-shift mask. This study was accomplished for 4 areas. First of all, we developed advanced Mosi etch process. Defects are generated under this etch process are not fatal. The thickness of hard defects were controlled thinner under this etch process compared with conventional etch process. Secondly, we studied cleaning process that has good performance on Cr : MoSi surface and a poor hydrophilic contrast to control side effect by etch process. Thirdly, we made inspection technique for detecting thin thickness hard defects. Lastly, we researched a repair technology that is effective in hard defects of thin thickness. The performance of the repaired pattern was verified by AIMS. In this study, it is researched that control shape, properties of defects to prepare a reliable repair and improved repaired photomask pattern reliability by 30% over.
In this study, the method to achieve the precise CD MTT (critical dimension mean to target) correction in
manufacturing attenuated PSM (phase-shift mask) is investigated. There has been a growing demand for
more precise Mask CD MTT control in recent years. The CD correction method has been developed and
applied to meet the tighter CD MTT specification [1]. However, the efficiency of the CD correction is greatly
affected by the repeatability of the CD measurement. The factors, which can have an influence on the CD
measurement, are the fluctuations of the pattern profile and the electron current of the SEM.
The conventional CD MTT correction method is basically to correct MoSi CD MTT by applying the
additional dry etch for MoSi based on Cr CD value. Therefore, the repeatability of the Cr CD MTT is the
crucial point for the accuracy of the final CD MTT correction. Although the Cr CD MTT is the crucial factor for
the successful CD MTT correction, it has the fluctuation due to the Cr pattern profile. If the Cr pattern profile
has low patterned angle after MoSi etch process, it can cause the focusing error in the CD measurement
using CD SEM. Therefore, a method to improve the reliability of the Cr CD MTT should be developed.
The IS and the normalized Delta CD concepts are adopted to obtain more reliable Cr CD MTT. The IS
refer the variation of the Cr CD MTT according to the difference in CD values with CD measuring thresholds.
The normalized Delta CD is obtained from the correlation of IS and Delta CD. Finally, the normalized Delta CD
is applied to correct the MoSi CD MTT by dry etch process.
The reduction of the Cr CD MTT fluctuation range is achieved by using the new CD correlation process
including IS and the normalized Delta CD. Consequently, the final MoSi CD MTT is improved 60% of range by
using the new CD correlation process.
We have investigated self-aligned resist patterning for a patterning accuracy of photo mask. Self-aligned resist
pattern can be formed by backside flood exposure on photo-mask. It had been already proved by the experiments with
248 nm light source exposure on binary (Cr on Quartz) and KrF attenuated phase shift masks. Attenuated phase shift
masks are generally composed of Cr/MoSiN/Quartz, MoSiN/Quartz, and Quartz layers. MoSiN layers of attenuated
phase shift mask have the optical property of 6% transmittance at 248 nm light source, and the interference of the 6%-
transmitted light makes the undesirable resist pattern profile on MoSiN-Quartz boundary. This paper shows the fresh
possibility of the self-aligned resist pattern fabrication on attenuated phase shift masks using backside flood exposure. To
solve the optical property of MoSiN layer, self-aligned resist patterns of KrF attenuated phase shift mask was fabricated
using 193 nm wavelength backside flood exposure and ArF attenuated phase shift mask used 172 nm wavelength. The
shorter wavelength than generally applied wavelength could minimize transmittance on MoSiN area. Besides we used
Negative PR to make the self-aligned resist pattern on exposed regions. These experimental concepts help to form the
selective PR patterning on only quartz regions of attenuated phase shift mask.
As the design rule of the semiconductor circuit shrinks, the specification for photomask becomes tighter. So, more
precise control of CD MTT (Critical Dimension Mean to Target) is required. We investigated the CD MTT control of the
attenuated PSM (Phase Shift Mask) by additional Cr dry etch. In conventional process, it is difficult to control CD MTT
precisely because about 5 factors - Blank Mask, E-beam writing, Resist develop, Cr dry etch, MoSiN dry etch - affect
CD MTT error. We designed the new process to control CD MTT precisely. The basic concept of the new process is to
reduce the number of factors which affect the CD MTT error. To correct CD MTT error in the new process, we
measured CD before MoSiN dry etch, and then additional corrective Cr dry etch and MoSiN dry etch was performed. So,
the factors affecting CD MTT error are reduced to 2 steps, which is additional corrective Cr dry etch and MoSiN dry
etch. The reliability of CD measurement before MoSiN dry etch was evaluated. The generable side-effect of the
additional corrective Cr dry etch was analyzed. The relationship between 'CD shift' and 'additional corrective Cr dry
etch time' was found for various patterns. As a result, accurate CD MTT control and significant decrease of CD MTT
error for attenuated PSM is achieved.
As the specification for photomask becomes tighter, it is strongly demanded for achieving precise CD MTT (critical
dimension mean to target) and enhanced defect controllability in photomask fabrication. First of all, it is necessary that
reducing the factors of CD MTT error and introducing the reliable method to correct CD error for accurate CD
requirement of attenuated PSM (phase shift mask). From this point of view, one of CD correction methods which consist
of Cr CD measurement step after resist strip (strip inspection CD: SI CD) and additional corrective Cr dry etch step was
developed. Previous SI CD correction process resulted in accurate CD control within the range of CD MTT. However it
was not appropriate for defect control due to additional resist processes for selective protection of Cr pattern during CD
correction process.
In this study, the method for achieving precise CD MTT by correcting CD error without any resist process is
investigated. It is not suitable for the CD correction process to control CD MTT precisely that Cr etched resist (etch
inspection CD: EI CD) is very vulnerable to E-beam scanning during CD measurement. Otherwise, photoresist after Cr
etch selectively shrinks via UV irradiation under ozone (O3) condition, which drives a reduction of CD MTT error as a
result of accurate CD measurement (UV-irradiation inspection CD: UI CD). Moreover, it is not necessary any resist
process for Cr protection due to UV irradiated resist as enough for a etch barrier. It is a strong advantage of novel CD
correction method. This strategy solves the problems such as both CD measurement error on the EI CD correction
method and defects originated from resist process on the SI CD correction method at once. For the successful
incorporation of UI CD correction method, several items related with CD should be evaluated: accuracy and repeatability
of CD measurement under UI CD, control of CD MTT and CD uniformity, additional corrective etch bias for UI CD,
independence of corrective Cr etch process from UV irradiated resist, isolated-dense CD difference,.. etc. In this paper,
strategy of design for the progressive CD correction method for defect-free photomask and process details will be
discussed.
In this study, the method for achieving precise CD MTT (critical dimension mean to target) in manufacturing attenuated PSM (phase shift mask) was investigated. As the specification for photomask becomes tighter, more precise control of CD is required. There are several causes to result in CD MTT error. In general mask patterning processes which are from blank material to dry etch, it is difficult to detect CD MTT error before final CD measurement and correct it. It is necessary to apply new process to mask production to correct CD error and control CD MTT precisely. Reducing number of factors which can have an effect on CD and introducing reliable method to correct CD error are important to achieve accurate CD MTT. For the correction of CD error, the reliability of CD in each measurement step such as resist CD or Cr CD before and after resist removal and effect on items related with CD like CD uniformity, isolated-dense CD difference, etc should be considered and evaluated. In this method to correct CD MTT error, Cr CD after removing resist was measured before MoSiN dry etch and additional corrective Cr dry etch using Cr CD information was applied to cancel CD error and then MoSiN dry etch was followed. In this case, factors affecting final CD are additional corrective Cr etch and MoSiN etch. The relationship between CD shift and corrective Cr etch time for masks with various pattern densities was found and necessary corrective Cr etch time was applied to CD correction process. The CD MTT error is canceled by additional corrective Cr dry etch step. As a result, accurate CD control and significant decrease of CD MTT error for attenuated PSM is achieved through the use of this CD correction method.
KEYWORDS: Ions, Ultraviolet radiation, Oxygen, Chemical analysis, Contamination, Phase shifts, Photomasks, Air contamination, Atomic force microscopy, Transmission electron microscopy
The critical source of haze contamination which mainly occurred on MoSiN surface and the interface of MoSiN and quartz is known as sulfuric ions remained after mask process. In this experiment, the UV treatment with oxygen gas was carried out before and after wet cleaning process for reducing residue ions from mask surface, and the effect with the sequence of UV treatment and wet cleaning was investigated. The composition of amorphous MoSiN layer was slightly modified by 172nm UV treatment with oxygen gas, and the amount of chemical residue ions after wet cleaning which use the piranha and SC-1 was reduced according to the transformation of surface composite. And also the relation of the surface transformation and the phase shift after SC-1 cleaning was evaluated.
In this study we investigated the defect due to pellicle frame materials for repeating exposure in months. Defects were found in the sub-pellicle and the defect density was high in the 4 corners compared to the center of the mask. The defects grew on MoSiON or the interface Quartz and MoSiON film, and the defect size was below 0.5 um. By analyzing with Raman Spectroscopy, defects consist of Ammonium Sulfates, Melamine Formaldade Resin and KClO3. The evaluation method for cleaning process and pellicles was Ion Chromatography. According to Ion Chromatography analysis, the main composition of defect was substances of pellicle frame materials. Also we confirmed the pellicle frame effect with the exposure test.
In this study, Cr defects resulted from high voltage E-beam writing in high Cr load Logic Mask were investigated. The Cr defect, which is a damage of anti-reflection layer on Cr, is mainly found in isolated Cr patterns of high Cr load Logic Mask. This defect appears under high voltage E-beam writing with high dose and dry etch process. High accelerating voltage and dose of E-beam writing decrease the thickness of remaining E-beam resist after developing. These phenomena are more significant in high Cr load Logic Mask consisted of isolated Cr patterns. Because the resist thickness of isolated Cr pattern is not enough for enduring dry etch process-induced damage, Cr surface is damaged during etching. Consequently, the Cr surface damage of high Cr load Logic Mask is related with voltage and dose of E-beam and dry etch process time. To prevent these defects, low accelerating voltage and dose of E-beam and low thickness of Cr layer to increase dry etch process margin are necessary.
It is required that CD uniformity in the mask fabrication process should be controlled much more tightly for manufacturing mask to meet below 0.13um design rule of photolithography. The first factors that affect CD uniformity on mask are resist thickness, range, and uniformity of coating temperature, etc. The second factors are fogging effect happening during E-beam writing and CD error caused by E-beam stitching in local area. So, It is on checking and evaluating new equipments as well as suitable process condition. The third is develop process factor that the space CD of mask center area is larger than that of edge area in spin type develop process. Various process recipes and chemical spraying methods is also on applying and evaluating to solve the problem like this. The forth is dry etch factors which are CD error resulted from the unstable plasma condition, inappropriate etch time, error factor from the poor resist selectivity, and CD difference caused by non-optimized exhaust condition in etcher. In this paper, the third factor is discussed, and the method to optimize develop process is studied and evaluated
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