As we approach the 65nm node, the impact of the image imbalance phenomenon in phase shift mask lithography is proving to have a serious impact on the robustness of the phase shift mask solution. In this work we describe a new concept for the phase shift imbalance correction. The method is based on an interference concept that allows the manipulation of the image intensity by placing sub resolution features within the zero phase regions. Rigorous 3D simulations illustrate the reduction in the intensity of the 0 degree phase regions to match the intensity of the 180 degree phase intensity, effectively correcting for the image imbalance. We show that the phase shift mask low sigma illumination conditions reduce the risk of printing these sub-resolution binary features increasing the flexibility to vary the size of the feature based on circumstances to fine tune the correction locally.
Each new technology node tests the limits of optical lithography. As exposure wavelength is reduced, new imaging techniques are needed to maximize resolution capabilities. The phase shift mask (PSM) is one such technique that is utilized to push the limits of optical lithography. Altering the optical phase of the light that transmits through a photo mask can increase the resolution of a lithographic image significantly. There are several types of phase shift mask and each has a general charateristic in which some transparent area of the mask are given 180° shift in optical phase relative to other nearby transparent areas. The interaction of the aerial images between two features with a relative phase difference of 180° create interference regions that can be used to printed images much closer together and with an increased depth of focus than that of a standard chrome-on-glass mask. An AAPSM is fabricated using a subtractive process in which the quartz substrate is etched to a given depth to produce the desired phase shift. However, intensity imbalances between the etched and non-etched regions due to sidewall scattering can cause resolution, phase and placement errors on the wafer. One method to balance the transmission is 40 nm undercut with 16 nm shifter width bias. Based on our previous study, 40 nm undercut with 16 nm shifter width bias showed an improved balance of intensities between the etched and non-etched regions. The object of this experiment is to implement the AAPSM with 40 nm undercut and 16 nm shifter width bias in SRAM product and the exposure wavelength is 193 nm. The main purpose is to proof the technology of AAPSM with 40 nm undercut and 16 nm shifter width bias in real product. Also verifying all issue of AAPSM in production. In this study, the image imbalance has been corrected via 40 nm undercut and 16 nm shifter width bias, and the DOF of AAPSM for wafer print performance is larger than binary mask. The DOF of AAPSM is about 0.5 μm and the conventional binary mask is 0.3μm.
In our previously published work, we investigated alternating-aperture PSM image intensity imbalance as function of various mask and optical parameters using rigorous electro-magnetic field (EMF) simulations. Results suggested that the imbalance could be effectively compensated through application of an optimized combination of undercut and a constant phase-shifter bias. In the effort of development and implementation of a production-ready image imbalance correction methodology, it is important to validate the accuracy of simulation-based predictions through correlation of results to experimental data. For this purpose, a test reticle containing various mask parameters as variables was designed and manufactured. The experimental data was obtained from SEM measurements of the exposed wafers, and results were compared to rigorous EMF simulation data. Based on results obtained, we propose and validate an image imbalance correction methodology to be implemented within the framework of the PSM - OPC manufacturing flow.
In this paper, we evaluate various strong and weak resolution enhancement techniques in the context of 65nm technology node requirements. Specifically, we concentrate on a simulation-based performance comparison of the dark-field alternating aperture and chrome-less shifter-shutter phase shifting masks (AAPSM and CLM respectively) for imaging of the critical gate level. Along with the through-pitch aerial image quality, the mask error enhancement factor, proximity effects, and the overall process latitudes are compared. Results show that while there might be multiple approaches in 193nm lithography to pattern isolated and semi-isolated pitches, it is necessary to utilize strong resolution enhancement in order to resovle dense pitches and achieve a sufficient common process performance with required CD control for the 65nm node.
The deployment of 157nm lithography for manufacturing of integrated circuits is faced with many challenges. The 65 and 45nm ITRS nodes, in particular, require that the lithographic imaging technology be pursued to its theoretical limits with full use of the strongest resolution enhancement techniques. Stringent demands are therefore placed on the quality of the imaging optics to attain the optimal image fidelity for all critical IC device structures. Besides aberrations and light scatter in projection optics, image quality is also strongly influenced by the dynamics of the wafer and reticle stage. The tradeoffs involved in increasing scan speeds and exposure slit-widths, to achieve the ever-important productivity improvements as well as aberration, distortion, and pulse-energy averaging, must be carefully gauged against the image quality impacts of scan-induced errors. In this work, we present a simulation methodology, based on incoherent image superposition, for treatment of the general aerial image effects of transverse image-blur in two dimensions. Initial simulations and experimental results from state-of-the-art 193nm scanner exposures are discussed. The requirements for the transverse image stability during a step-and-scan exposure are defined in the context of 193nm and 157nm lithography, based on generalized image contrast and process window criteria. Furthermore, careful consideration of actual mask layout (post resolution enhancement and optical proximity correction) is necessary in order to understand the implications on CD control. Additionally, we discuss the contributors to transverse image blur in scan-and-repeat lithography, and show that the fading requirements for 65nm and 45nm node imaging notably differ from predicted exposure set-up and process contributions in manufacturing. The total fading budget, or tolerance, for the 65nm node is 15nm, and less than 10nm for the 45nm node given the present imaging strategy assumptions. This work concludes that image-blur contributors must be well controlled, and as such are enablers of 65nm and 45nm lithographic imaging.
Simulation-based techniques assisted mask and wafer metrology and inspection have become increasingly important with the growth of the sub-wavelength gap in optical photolithography. This paper describes a method for full-chip layout verification based on fast calculation of the mask error enhancement factor (MEEF). Because of the significant amount of MEEF computations necessary for large layouts, we discuss a methodology that takes advantage of distributed computing environment to significantly shorten the total run time. Additionally, MEEF calculations can be selectively reduced to layout locations that meet specific criteria, which allows to not only reduce the overall simulation time, but also to decrease the output data volume transferred to the mask inspection equipment. After MEEF is calculated, a SQL database is used to generate a summary report and to efficiently locate high-MEEF areas, which could be sent in a form marker files to metrology tools.
Over recent years, there has been a number of publications generally describing and characterizing the image imbalance phenomenon in phase shifting masks. In this work, we concentrate on the evaluation of various alternating aperture PSM design parameters and their impact on image imbalance in the context of the 65nm technology node. The study is based on rigorous electro-magnetic field (EMF) simulation of light scattering in 3D mask topographies using EM-Suite software from Panoramic Technology. Among evaluated design parameters are: Cr feature size, pattern pitch, shifter width bias, shifter height, and undercut size. Additionally, the correlation between the mask parameters and image imbalance is examined as a function of optical settings such as NA, sigma, defocus and the image threshold level.
In this study, process latitude, mask error enhancement factor and iso-dense bias have been experimentally measured as a function of the KrF excimer laser bandwidth. The experiment results are in agreement with photoresist simulations over a range of imaged nominal feature sizes from 120nm to 300nm at 0.6/0.75 NA/(sigma) . The mask error enhancement factor (MEEF) is shown to vary by approximately 2.3 percent for 160nm and 3.3 percent for 150nm isolated lines per 0.1pm of excimer-laser bandwidth, characterized by the full width at half maximum (FWHM). The 180nm line iso-dense bias exhibits a shift of approximately 2nm per 0.1pm FWHM. Under the given process conditions, linear empirical relationships are derived for the dependency of MEEF and iso-dense offset on FWHM excimer-laser spectral width for a range of imaged CDs. Such considerations can be used to augment the existing predictive CD-control estimation and model-based optical proximity correction.
In this paper, various optical proximity effects are evaluated as a function of spectral properties of excimer laser illumination. Sensitivity of linewidth biasing and line-end pullback to spectral bandwidth and its variations is investigated using computer simulations based on PROLITH software. Studies are performed for isolated and dense lines ranging in size from 150nm to 130nm using projection lens numerical aperture of 0.7 and KrF illumination. Results show that a non-linear, through-pitch critical dimension sensitivity to laser bandwidth variation introduces additional feature biasing, which can not be compensated with optical proximity correction techniques, and can result in an additional shift of the iso-dense bias. Also, line-end pullback of isolated lines exhibits a non-linear response to bandwidth resulting in up to 7nm of pullback per 0.1pm of bandwidth change.
Bandwidth of a laser spectrum is generally specified in terms of the full-width-at-half-maximum (FWHM) metric. Another bandwidth specification is based on the 95% integral energy (E95%) of the spectrum. While providing a more complete information about the spectral shape, E95% bandwidth is very sensitive to small changes in spectral background intensity. In this work, both bandwidth specifications and their effects on aerial image properties are evaluated using computer simulations. Also, in order to obtain a more comprehensive understanding of illumination spectrum effects on lithographic imaging, aerial image sensitivity to the shift of central wavelength and to the change of spectral background intensity is investigated. Results show that the overall shape of the laser spectrum is critically important, and that the E95% metric is more suitable for bandwidth specification.
Quantification of projection lens aberrations in lithographic exposure systems has gained significant importance due to more stringent critical dimension control and image fidelity requirements. As linewidths shrink, the impacts of wavefront aberrations on imaging become more pronounced. Therefore, minimization of the wavefront aberrations across the image field is desired and has led to the development of a number of measurement approaches. The proposed techniques have been evaluated extensively for characterization and specification of lens systems, adjustments, matching, and periodic control and monitoring of lithography systems for volume production. In this study, we discuss the contribution of excimer laser bandwidth towards lens aberrations. We carry out simulations of the effects of image contrast on conventional projection patterning, to evaluate the degree of aberation-induced linewidth changes depending on image contrast level. Also, experiments have been conducted to measure the response of wavefront error as a function of spectral bandwidth for a 0.6NA stepper and scanner. Depending on the field location, a positive relationship is observed between the measured aberration level and bandwidth. We propose a formalism to correlate the aberration measurement with aberration response to wavelength offset, presented elsewhere.[2] The wavefront error, in this work, is measured using a commercially available in-situ interferometric technique, whose response is largely insensitive to focal plane changes and partial coherence.
In many respects, excimer lasers are almost ideal light sources for optical lithography applications. Their narrow bandwidth and high power provide tow of the main characteristics required of a light source for high- resolution imaging. However, for deep-UV lithography projection tools with no chromatic aberration in the imaging lens, even the very narrow bandwidth of an excimer laser may lead to image degradation.
Sub-resolution assist features can significantly improve depth of focus and uniformity of critical dimensions of contact windows especially when combined with appropriately optimized conditions. In this paper, the placement and dimension control of assist features for 160nm contact windows are studied and analyzed using 193 nm lithography in conjunction with state-of-the-art single layer resist. Our study is based on comparison of simulation and experimental data obtained form critical dimension measurements with varying exposure dose, focus, and in different environments. Computer simulations are performed using such commercial lithography software tools as Prolith and Solid-C. Along with optical proximity corrections, we use different conventional and off-axis illumination conditions which increases depth of focus of contact windows and improves the overall process latitude. A test photomask with different configurations of contact windows with and without assist features has been specifically designed for this study. The results have shown that when used with appropriate illumination conditions, especially quadrupole off-axis, sub-resolution assist features increase the depth of focus of contact windows by about 0.3 micrometers , significantly decrease the proximity effects, and improve the overall process latitude.
The properties of sub-resolution assist features for 193nm wavelength contact window lithography have been investigated. A test mask consisting of a variety of window and assist feature sizes and pattern density environments was fabricated and printed. Windows, 160nm in diameter, where exposed in conventional and quadrupole off-axis illumination. Results show a substantial increase in depth- of-focus when quadruple illumination and assist features were employed, when compared to conventional illumination and standard contacts. The improved process latitude is especially apparent in thicker resist formulations, which are required for etching. By employing improved resists with assist features and quadrupole illumination, isolated 160 nm contacts have been fabricated in 510 nm thick resist on 1000 nm SiO2, without anti-reflective coatings. The depth-of- focus is approximately 0.5 microns. BY lowering the numerical aperture of the projection optics, the measured depth-of-focus is unchanged, but assist feature printing can be significantly reduced. Preliminary results of 160 nm windows etched into oxide show that resist loss may be unacceptable with conventional pattern transfer processes.
A resolution enhancement technique suitable for Deep-UV microlithography based on coherent multiple imaging (CMI) will be described. We showed recently that a Fabry-Perot etalon inserted between the mask and the projection lens in an optical stepper is able to simultaneously enhance the resolution and depth of focus of an aerial image. Since the multiple images of the mask pattern created by the etalon are added together coherently, the final image profile is very sensitive to the initial phase conditions. It is possible to simulate this coherent multiple imaging techniques using a simulation model which either superimposes separate output electric fields or by applying an appropriate transmission-phase pupil plane filter in the simulator. The first approach, however, requires a modification of the simulation software which allows output of the electric field profile, while the second approach can be used with a conventional commercial lithography simulator. In this paper computer simulations for isolated and extended contact hole arrays are used to demonstrate that the CMI method can enhance resolution by 18 percent while maintaining or even increasing the DOF of the aerial image. It is also shown that the high intensity side lobes generated by the filter nc abe eliminated by means of a phase shifting mask or by reducing the spatial coherence of the illumination source. The optimum value of spatial coherence was found to be 0.28. In this case the side lobes disappear, and the intensity of the main peaks doubles. The impact of this technique on image intensity is also discussed.
Combining assist features with appropriate off-axis illumination conditions can significantly improve depth of focus and uniformity of critical dimensions of contact windows. It is known that sub-resolution assist features modify the environment of isolated features in a fashion that they appear dense. In recent years the impact of assist features was mostly studied for gate-level lithography. In this paper the placement and dimension control of assist features for contact windows are examined and analyzed using 193 nm lithography in conjunction with a state-of-the-art single layer resist. Our study is primarily done for 160 nm contact windows, and it is based on experimental data obtained from critical dimension measurements with varying focus, exposure dose, and in different environments. Along with optical proximity corrections we use off-axis illumination technique which increases depth of focus of contact windows and improves the overall process latitude. Specifically for this study we have designed a test photomask with different geometries and pattern densities of contact windows with and without assist features to be used at 193 nm wavelength. To study the proximity effects, different sizes of assist features were used as well as the distances of assists from the main feature were varied. The results have shown that while increasing the process latitude for the primary feature using assist slots in combination with off-axis illumination, the resist thickness and contrast are limiting the assist feature dimensions that can be used. Assist features appear to significantly increase critical dimension uniformity of the contact windows when using both conventional and off-axis illumination techniques, and they dramatically increase the common exposure dose latitude for contact windows with densities from near-isolated to dense, decreasing the proximity effects. Assist feature technique combined with quadrupole illumination demonstrates about 0.3 micron improvement in depth of focus for every type contact window pattern used.
Optical microlithography is continuing to play a key role in the fabrication of feature sizes in the 0.25 - 0.1 micrometers regime as the semiconductor industry enters manufacturing of the gigabit chip generation. Several important advances in technologies are needed to achieve this goal. These include the use of excimer lasers and optical resolution enhancement schemes, which will be addressed in this work.
Variations of lens aberrations of optical projection systems can have undesirable effects on critical dimension (CD) uniformity and depth of focus (DOF) of printed microelectronic circuit patterns. The principal objective of this paper is to investigate how lens aberrations along with variations of partial coherence of the illumination source of an optical stepper affect critical dimensions of dark gate lines when using conventional and phase-shifting masks (PSMs) with and without optical proximity corrections (OPC). The investigations are performed using lithography simulation software tools which help to evaluate different optical projection systems and diverse types of masks. For the purpose of accurate evaluation of the effects of different types of aberrations on printed patterns, 37 Zernike polynomial coefficients representing lens aberrations were normalized using the Strehl test. The impact of aberrations on 0.25 micrometer and 0.18 micrometer dark gate lines is studied by analyzing data obtained from simulations using four different optical projection system set-ups. The results show that lens aberrations do not significantly reduce CD uniformity and DOF or destroy the process window if we use an optimal numerical aperture (NA) and high resist contrast. It was observed that high resist contrast is more important than NA in terms of dealing with the impact of lens aberrations. The effectiveness of masks with OPC for aberrated images was analyzed, and we have been able to show that OPC does not always improve CD uniformity and DOF. This paper describes methods for maintaining tighter control of CD errors in the manufacturing process of integrated circuits using optical lithography.
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