With decreasing Critical Dimensions (CD), the negative influence of line edge roughness (LER) and line-width
roughness (LWR) on CD uniformity and mean-to-target CD becomes more pronounced, since there is no corresponding
reduction of roughness with dimension reduction. This applies to wafer metrology as well as to mask metrology. In
order to better understand the types of roughness as well as the impact of the CD-SEM roughness measurement
capabilities on the control of the mask process, the sensitivity and accuracy of the roughness analysis were qualified by
comparing the measured mask roughness to the design for a dedicated LER test mask. This comparison is done for
different LER amplitude and periodicity values and for reference structures without nominal LER using the built-in CD-SEM
algorithms for LER characterization.
This paper describes a method to automatically distinguish between line and space for 1:1 line space patterns in mask
metrology. As the number of measurements typically performed on a reticle is significantly higher than on a wafer,
automated CAD based CD-SEM recipe creation is essential. Such recipes typically use synthetic pattern recognition
targets instead of SEM based pattern recognition targets. Therefore, a possible different contrast between lines and
spaces on a mask cannot be utilized for distinguishing lines from spaces. We demonstrate an algorithm solution based
on the analysis of the SEM waveform profiles to identify potential L/S mix-ups and correct them automatically. The
solution allows fully automated CAD based offline recipe creation with a high success rate of distinction between lines
and spaces for 1:1 pitch cases without the necessity of editing recipes on the tool in advance of performing the
measurements.
As optical lithography is extended to the 130 nm generation and beyond, demanding requirements are placed on mask pattern generators to produce quartz substrate masks. This paper reports on the lithography and critical dimension (CD) performance of the MEBES 5500 mask pattern generator. Compared to previous MEBES tools, this system employs a new high-dose electron gun and column design. We summarize experiments relating lithographic quality to increased dose and the effects of spot size on lithography. Methods to reduce beam-induced pattern placement errors are reviewed. A new graybeam writing strategy, Multipass Gray-II, is described in detail. This strategy creates eight dosed gray levels and provides increased writing throughput (up to 8X compared to single-pass printing) without loss of lithographic quality. These experiments are performed with ZEP 7000 resist and dry etch process; improvements in CD control have been achieved by optimizing the process. A consequence of the improvement in CD control and throughput is improved productivity in generating 180 nm devices.
Critical dimension (CD) control and resolution requirements of advanced photomasks require a new class of fabrication processes. These include the use of higher contrast resists and low etch bias processes such as plasma etching for patterning chrome films. Previous work has shown that ZEP 7000 resist and ICP dry etching of chrome provide the process latitude needed to meet 180 nm mask requirements and beyond. However, due to the loading effects, the deviation of the CD from the target value is a function of the chrome loading on the plate when using dry etching. Therefore, CD control must occur by varying the exposure dose or the develop time based on the pattern loading of a particular mask level. By understanding the relationships between the change in CD with respect to dose, develop time and pattern loading, models can be created which accurately predict the required parameters to tightly control CD performance independent of dry etch loading effects. In this paper a production process is described which utilizes ZEP 7000 and ICP dry etching. A series of experiments have been run to characterize the change in CD based on both dose and develop time. Then a matrix of experiments were run to determine the effect of pattern loading on CD. A predictive model was generated from the DOE data which accurately predicts the dose and develop time needed to meet the CD targeting requirements for any given mask level regardless of pattern density. The model was then verified on production mask levels of randomly varying pattern density.
Leading edge technologies require continually shrinking design grids due to the demands of decreasing minimum feature size and higher resolution. Using conventional raster-scanned exposure tools to place these patterns on photomasks result in longer write times, because linear decreases in address result in exponential increases in write time. This phenomenon can be compensated for by changes in writing strategies. Multipass gray is one method of drastically improving throughput at small addresses while retaining lithographic quality.
Advanced reticle specifications for resolution, critical dimension (CD) control and CD linearity of 180-nm generation devices require large-scale improvements to maskmaking processes. The approximately 200 nm of bias required with widely used wet etch processes will not meet these specifications. A solution to the high bias requirement of wet etch processing is to implement a plasma or dry etch process. Plasma etch processing has been shown to have little or no undercutting. However, some of the standard resists used with electron beam (e-beam) exposure of photomasks have poor dry etch characteristics. ZEP 7000 is an e-beam resist that has good dry etch resistance while exhibiting superior lithographic quality. In this paper, processes using ZEP 7000 resist and inductively coupled plasma (ICP) etching are described. The combination of these operations can result in zero bias or near zero bias process with e-beam exposure of photomasks. While the required dose for ZEP 7000 is higher than that of PBS, the higher beam current capability of newer e-beam systems, together with multipass writing strategies, enables the use of these slower resists without throughput penalty. Optimization of the development process was done using a two-component solvent developer. A puddle process was investigated for optimizing sensitivity, edge slope, resist loss, mean-to-target control, and CD uniformity. Dry etching with ICP has been shown to etch chromium films with good selectivity to the resist, give a highly anisotropic etch, and, most significantly, show insensitivity to loading effects. The net result of this effort is the development of a process that gives excellent CD control when meeting MEBES 5000 system requirements for 180-nm maskmaking. Data on resolution, CD control, and defects are presented using this process.
As requirement of CD uniformity on photomask continue to tighten with advanced logic and memory devices, new process technologies will be needed to be developed to address the gap of process capability. For instance, a less than 20 nm CD range will be required on a 0.18 micrometer generation logic devices with a nominal field area of 120 X 120 mm. New technologies such as high energy e-beam write (to reduce forward scattering), advanced e-beam photoresist and plasma etch processes are currently being developed to achieve such stringent CD uniformity specifications. One of the key issues of plasma etch technology is related to microloading effects which accounts for a major portion of CD budgets. In this work, an engineering test mask was designed to identify etch microloading mechanisms and to improve performance of a standard Magnetic-Enhanced Reactive Ion Etch (MERIE) process. Additional comparison of CD microloading was also made with an Inductively-Coupled Plasma (ICP) etch process.
The ALTA 3500, an advanced scanned-laser mask lithography tool produced by Etec, was introduced to the marketplace in September 1997. The system architecture was described and an initial performance evaluation was presented. This system, based on the ALTA 3000, uses a new 33.3X, 0.8 NA final reduction lens to reduce the spot size to 0.27 micrometers FWHM, thereby affording improved resolution and pattern acuity on the mask. To take advantage of the improved resolution, a new anisotropic chrome etch process has been developed and introduced along with change from Olin 895i resist to TOK iP3600 resist. In this paper we will more extensively describe the performance of the ALTA 3500 and the performance of these new processes.
The technology in use in today's mask shop may not be adequate to meet 180 nm production requirements. In particular, requirements for linewidth control, linewidth uniformity, and registration are tightening at a breakneck pace. In the past, incremental improvements to registration and linewidth have been adequate to keep pace with steadily evolving mask requirements. This paradigm of continuous incremental improvement is not longer a valid model. Mask writers are needed that can deliver a higher dose to support advanced resists for superior critical dimension (CD) control, write faster to compensate for shrinking device sizes, and incorporate advanced calibration and error control schemes to improve placement accuracy. This paper describes key electron-beam pattern generation activities necessary to meet 180 nm mask requirements. This includes testing and implementation of multipass graybeam to improve throughput at lower addresses without compromising lithography quality, a new resist and process capable of supporting dry etching, and a data path capable of supporting addressing to 10 nm. Multipass gray (MPG) writing strategy was introduced with the MEBES 4500S. The ability to deliver a 4X improvement in dose while improving throughput is a significant advantage over previous MEBES systems. Because MPG is used in conjunction with offset scan voting, improvements in registration performance and a reduction in butting of over 50 percent have been demonstrated. Some of the process improvements attributed to a high dose mask writer are also documented in this paper. CD uniformity improvements with ZEP 7000 and dry etch at a 720 nm nominal feature size and smaller are also discussed in some detail.
As device design rules continue to shrink, on-mask Cr structures must experience a corresponding reduction in size. Although 0.25 micrometer design rules require only 1 micrometer Cr features, the use of OPC structures, which may be needed to minimize line foreshortening and corner rounding, necessitate features to be etched into the Cr which are significantly smaller than this. This need, coupled with the demand for reduced CD bias and improved CD uniformities, requires the use of an alternate chrome etch technology. Plasma etching of Cr can be highly anisotropic, greatly reducing the etch under cut which is responsible for the CD bias typically associated with wet etching. Reactive ion etching (RIE) can provide significant enhancements in the capability of replicating micron and sub-micron features, but the Cr etch rate non-uniformity which is typical of this technique can translate into a CD nonuniformity. This is due in part to the relatively high pressure of operation (50 - 100 mTorr which is necessary to reduce the self generated dc voltage And which minimizes the photo resist etch rate. Recently, high density plasma sources, such as inductively coupled plasma (ICP), have become available which have the ability to operate both at low pressures and high plasma density while maintaining a low and controllable dc voltage. The low pressure operation significantly improves the etch rate uniformity and consequently the CD uniformity. In this study a design of experiment (DOE) is used to investigate the parameter space associated with the dry etching of Cr using an ICP source. The responses of Cr etch rate, selectivity to photo resist, CD uniformity and mean CD to target are studied, and from this an optimized parameter space is defined. Within this space the effect of overetch, dc voltage and pattern loading on the CD uniformity are also investigated. The role played by the photo resist profile in determining the Cr etch profile is also studied and preliminary measurements are made to understand the effect of the above parameters on the mask CD bias.
As device design rules continue to shrink, on-mask Cr structures must experience a corresponding reduction in size. Although 0.25 micrometer design rules require only 1 micrometer Cr features, the use of OPC structures, which may be needed to minimize line foreshortening and corner rounding, necessitate features to be etched into the Cr which are significantly smaller than this. This need, coupled with the demand for reduced CD bias and improved CD uniformities, requires the use of an alternate chrome etch technology. Plasma etching of Cr can be highly anisotropic, greatly reducing the etch undercut which is responsible for the CD bias typically associated with wet etching. Reactive ion etching (RIE) can provide significant enhancements in the capability of replicating micron and sub-micron features, but the Cr etch rate non-uniformity which is typical of this technique can translate into a CD non-uniformity. This is due in part to the relatively high pressure of operation (50 - 100 mTorr) which is necessary to reduce the self generated dc voltage and which, in turn, minimizes the photo resist etch rate. Recently, high density plasma sources, such as inductively coupled plasma (ICP), have become available which have the ability to operate both at low pressures and high plasma density while maintaining a low and controllable dc voltage. The low pressure operation significantly improves the etch rate uniformity and consequently the CD uniformity. By coupling this ICP plasma source with a non-contact backside photomask handling system and a true multi-station 'cluster tool.' In this study a design of experiment (DOE) is used to investigate the parameter space associated with the dry etching of Cr using an ICP source. The responses of Cr etch rate, selectivity to photo resist, CD uniformity and mean CD to target are studied, and from this an optimized parameter space is defined. Within this space the effect of overetch, dc voltage and pattern loading on the CD uniformity are also investigated. The role played by the photo resist profile in determining the Cr etch profile is also studied, and preliminary measurements are made to understand the effect of the above parameters on the mask CD bias.
Advanced photomask fabrication specifications for 180 nm generation devices require large-scale improvements to resolution, critical dimension (CD) control, and CD linearity. These requirements mandate the adoption of zero bias processes. The approximately 200 nm of bias required with widely used wet-etch processes cannot meet these advanced specifications. Plasma-etch processing provides an alternative to wet etching and has been shown to have little or no undercutting. However, some of the standard resists used with electron-beam (e-beam) exposure of photomasks have very poor dry-etch characteristics. In this paper, EBR-900 M1 and ZEP 7000 resist processes, in conjunction with inductively coupled plasma (ICP) etching, are described. EBR-900 is a DNQ-novolac i-line resist. The exposure dose and the development process were investigated using a caustic-based developer optimized for e-beam exposure. ZEP 7000 is a polymer of methylstyrene and chloromethyl acrylate, which uses a solvent-based developer. Spray and puddle processes were both investigated for their influence on resist sensitivity, edge slope, resist loss, and CD uniformity. While EBR-900 and ZEP 7000 are less sensitive than PBS, the higher current delivery of newer e- beam systems combined with multipass gray (MPG) writing strategies result in improvements to the lithographic performance without incurring any throughput limitations. MEBES 4500S is the target platform for these processes. It has the gun brightness and writing strategy (MPG) needed to expose these resists while maintaining high throughput.
The advanced requirements for resolution, critical dimension control, and linearity on photomasks require chromium etch processes, which are highly anisotropic and extremely uniform. They must also allow lithographers to expose the resist at the iso-focal point of the exposure system. A reactive ion etching (RIE) process of chromium films, previously reported, met some of these demands. However, it was reported that system loading effects significantly reduced the etch rate, etch rate uniformity, and CD uniformity. An alternative plasma etch system technology, inductively coupled plasma (ICP), has been investigated, which makes it possible to achieve much higher plasma densities, operate at lower pressures, and control ion energies independently. The combination of these features minimizes loading effects, makes it easier to control selectivity, accelerates etch rates, decreases undercutting,a nd improves etch uniformity. This allows the maskmaker to transfer the resist image into the chrome with minimal nominal CD shift and degradation of CD uniformity. Furthermore, with little or no undercutting, resolution and CD linearity are greatly improved. Results using the ICP configuration will be presented and compared with the RIE process. Preliminary studies of defects will be presented. Defect densities will be quantified using a plasma etch process and compared to a wet etch process. Sources of defects and possible solutions to defect reduction will be discussed.
The design rule requirements and error budget allocation for maskmaking have made the mask a critical component in the fabrication of 250 nm design rule IC devices. The MEBES 4500 raster-scan reticle writer was designed to meet the mask requirements for pilot production of this generation of devices. In this paper, we will review the IC device and user requirements that drove the design criteria of the MEBES 4500 system. The architecture of the MEBES 4500 system is described and compared to these design criteria. MEBES 4500 perfonnance results during development, manufacture, and installation are also compared to the commercial requirements of 250 nm design rule ICs.
To meet the advanced CD uniformity and resolution requirements of state-of-the-art maskmaking, dry chrome etch processing may be required. Dry etching is a more anisotropic process, significantly reducing etch undercut. The absence of undercutting allows the lithographer to image the resist at the iso-focal point, eliminating the need to underexpose to maintain CDs. Also, dry etch parameters can be precisely controlled via a microprocessor- controlled etch system with a highly accurate parameter-metering system that ensures greater process control. Using design-of-experiment methodologies, a chrome plasma etch process (using OCG-895i) was developed. This work proves the feasibility of plasma etching chromium patterns on photomasks. The results show an etch that has excellent uniformity, is anisotropic, and has excellent edge quality. Also, resist selectivity is high for the etching of thin chrome films. SEM results show a significant reduction in the bias needed to achieve nominal CDs. As with many dry etch processes, loading and microloading effects (i.e., localized pattern density effect on etch rates) are a concern. Initial investigations of loading and microloading effects were conducted. Results suggest that due to the high anisotropy of the etch, microloading is not an issue. However, plate loading (or the amount of chrome removed) increases etch times and can result in radial etch patterns. Loading effects must be minimized or eliminated to optimize etch uniformity.
It has been shown that mask composite pattern position errors can be reduced by more than 40% on the MEBES 4000 system if a reference grid is used to match a MEBES 4000 system to an independent metrology tool. It has also been shown that matching between MEBES systems can be significantly improved by use of the dynamic grid matching (DGM) feature of the MEBES 4500 system. Several methods of grid matching are possible on the MEBES 4500 tool, including generation of a physical reference artifact or 'golden plate.' This work defines a method to produce a golden plate artifact for use in system grid matching. The technique uses a second level (phase shift mask) alignment capability to a zero level target to place a reference grid pattern on the reticle. Subsequent exposures of this pattern overlaid on the same substrate with different orientations serve to reduce systematic and random errors of the exposure tool. The processed image can then be used as a reference artifact for different systems. If necessary, the procedure can be iterated to further improve accuracy. Results of this methodology to produce an artifact are presented as well as its application in system matching to reduce composite positional errors as measured by independent metrology tools.
Techniques have been developed that can quickly and accurately measure corner rounding and contact fill as key indicators of pattern fidelity. Using these techniques, we have examined writing variables for their effect on the lithographic quality of 1.0 micrometers contact. A small contact is perhaps the most demanding figure to achieve, so the results shown can be considered the worst case for 4X radicle manufacturing at 250 nm design rules. A MEBES 4500 was used as the writing tool, using PBS resist on quartz masks. Standard printing methods, single-phase printing (SPP) and multiphase printing (2X MPP) were examined. Results indicate that excellent corner rounding results can be achieved with small address sizes, regardless of the writing strategy or the dose used. As expected, larger spot sizes increase the amount of corner rounding, regardless of the address. As the pattern address is increased, judicious choices of spot size reduce potential pattern fidelity loss when imaging small contracts and other fine features. Multiphase printing is a technique that offers advantages to the user. Its use of offset scan voting (OSV) is a significant factor in reducing placement errors. MPP (2X) has an additional advantage of providing higher dosages. This provides flexibility in resist choices and in the selection of a process window. With 2X MPP, the user has a wide range of addresses and spot sizes that will give excellent results. The dynamic range of operating conditions possible with 2X MPP when writing 1.0 micrometers contacts is a reduced subset of those available using SPP, due to the 2X writing grid (output address). Implementation of 2X MPP has been limited on previous MEBES models due to increased write times of multipass writing. The MEBES 4500 data path supports 2X MPP with write times that approximate SPP. The practical operating envelope of both writing strategies are detailed in this paper. Overall, the MEBES 4500 has a large dynamic operating range. When used with a high resolution process, MEBES 4500 provides excellent pattern fidelity to support requirements of 250 nm design rules.
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