1. Field of the Invention
The present invention relates to aerial image measurement, and particularly relates to measurement of an aerial image produced by an optical lithography system.
2. Description of the Related Art
In the optical lithography system, the image quality of the aerial image is influenced by lens aberrations, illumination conditions, etc. The image quality can be evaluated by using a SEM (Scanning Electron Microscope) after exposing photo-resist coated on the wafer 1003 and developing the photo-resist. To save time and to reduce the influence of photo-resist properties, directly measuring aerial image 1008 is desirable. An aerial image 1008 is illustrated in FIG. 1B when the reticle 1002 has an object pattern (a transmittance pattern) 1005.
According to an aspect of the present invention, it is provided that an apparatus includes an aperture configured to transmit light of an aerial image, a detector configured to detect the transmitted light at a plurality of first relative positions to the aperture, a controller configured to control a second relative position of the aperture to the aerial image, and a processor configured to generate information about the aerial image based on data obtained from the detector at each first relative position by controlling the second relative position of the aperture and position data about the first relative position.
According to another aspect of the present invention, it is provided that an apparatus includes an aperture configured to transmit light of an aerial image, a detector configured to detect the transmitted light at a plurality of first relative positions to the aperture along a direction, a controller configured to control a second relative position of the aperture to the aerial image along the direction, and a processor configured to generate information about the aerial image based on data obtained from the detector at each first relative position by controlling the second relative position of the aperture.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Measurement of the aerial image 1008 can be performed by scanning the aerial image through the aperture 1011. The scanning can be performed by properly controlling a wafer stage on which the substrate 1000 is provided. The operations of scanning, data acquisition from the detector 1014, and output of measured image 1016 can be controlled by a controller 1015. The measurements system can be used to create an image profile, which can be used to evaluate the image quality of an optical lithography system.
The aperture 1011 can be a slit, which is extended in the y-direction, or a pinhole. In order to realize high resolution in the measurement, the aperture size can be sufficiently narrower than the image feature, which means that the aperture size could be in a sub-wavelength region.
For simplicity, the aperture 1011 is assumed to be a slit extended in the y-direction and the aerial image 1008 is also assumed to be one-dimensional, which is invariant in the y-direction. One-dimensional test patterns can be used for the purpose of an imaging performance evaluation. In
It should be understood that there is a difference between the aerial image 1008 and the measured image 1016 (i.e., the measurement result of the aerial image). The aerial image 1008 is an image that would have been formed on a wafer if the wafer had been positioned by a wafer stage beneath a projection lens. If it is measured using an aperture (a slit) of sub-wavelength size, the profile of the aerial image is subject to change because of inherent optical properties of the aperture.
The calculation, to obtain the actual aerial image that would have been created on the wafer if the wafer had been present based on the measured image data considering the optical properties of the aperture 1011, is called an image recovery system. Such calculation is executed to ensure high precision measurement.
The image recovery process might not be straightforward in an optical lithography system. Since the behavior of an image formation in the optical lithography system is non-linear, and governed by partially coherent imaging theory, it might not be possible to fully recover an original aerial image formed on a wafer using measured image data as an “inverse problem”, or based on MTF (Modulation Transfer Function) analysis as mentioned in U.S. Pat. No. 5,631,731 or U.S. Pat. No. 5,866,935.
The image recovery in this case requires massive calculations including iterations. The calculation process is illustrated in
The image recovery calculation can be composed of following two steps.
Step 1: L(u) and Φ(α) are deduced from IM(x) and F(α; ƒ). This calculation step is an inverse process and requires non-linear optimization with iterations.
Step 2: Then, I(x) is calculated using the above obtained L(u) and Φ(α). This calculation process is a forward process.
In “Step 1”, L(u) and Φ(α) are obtained as a result of optimization with iteration calculations. The optimization is targeted to minimize the cost function:
Cost Function=[ÎM(x)−IM(x)]2 (1)
where ÎM(x) is calculated using {circumflex over (L)}(u) and {circumflex over (Φ)}(α) which are intermediate states of L(u) and Φ(α), respectively, and are varied in an appropriate manner during optimization.
When the value of Eq. (1) takes its global minimum (ideally zero), the interim functions {circumflex over (L)}(u) and {circumflex over (Φ)}(α) should be equal to L(u) and Φ(α), respectively. After determining the optimum functional form for {circumflex over (L)}(u) and {circumflex over (Φ)}(α), they are substituted to L(u) and Φ(α), respectively, and used for the calculation of the “Step 2”.
It is known that the above calculations have the following problems. L(u) and Φ(α) are not simple functions, but are composed of numerous data points which need to be optimized in Step 1. On the other hand, the amount of data constituting the cost function (1) is very limited since only one data set for measured image is available. In other words, too many parameters need to be optimized considering the amount of data available for the optimization. Furthermore, this process might be susceptible to noise in the measurement data.
Exemplary embodiments according to the present invention will be described below with reference to the attached drawings. The same reference numerals denote the same members throughout the drawings, and a repetitive description thereof will not be given.
As described above,
The apparatus 5009 for an image measurement that enables accurate image recovery calculations will be described in detail.
Light beams that compose the aerial image 1008 pass through the aperture 1011 and a portion of transmitted light 1013 can reach a detector 5114. Instead of measuring the total intensity of transmitting light 1013, the detector 5114 can measure a portion of transmitted light 1013, where the portion is specified by the angle ξ or its direction cosine ƒ=sin ξ. The detector 5114 can detect the transmitted light at a plurality of first relative portions to the aperture 1011 along a direction (e.g., x direction). Position data about the first relative positions can be specified by using the angle ξ. The position data may be prepared as a data table before the detecting. The position data can be obtained every the detecting.
To measure the profile of the aerial image 1008 along, for example, the x-axis as shown in
The first relative position between the aperture 1011 and the detector 5114 can be maintained during each scanning operation. The scanning operation can be executed by a controller 5117 which controls a second relative position of the aperture 1011 to the aerial image 1008. Then, a measured image 5118, represented by JM(x, ƒ), can be created mainly by the portion of transmitted light specified by ƒ=sin ξ.
In this embodiment, the scanning operation is repeated for plural times (K times) after changing the first relative position between the aperture 1011 and the detector 5114. The first relative position can be controlled by a detector position controller 5115. As a result, a total of K data for JM(x, ƒ) are obtained with different values of ƒ=sin ξ. Note that the K image profiles are different from each other as far as the associated value of ƒ=sin ξ are different. Instead of moving the detector 5114 to change the first relative position, a detector array which comprises a plurality of image pick-up devices can be used. Prior to the scanning operation to change the second relative position, the detector 5114 can detect the transmitted light at the plurality of the first relative positions while maintaining a certain second relative position of the aperture 1011, and then the second relative position can be moved. The scanning operation to change the second relative position and the detecting operation to detect the transmitted light at the plurality of the first relative positions might be substantially executed at the same time by using the detector array.
The detector 5114 and the detection position controller 5115 can both be attached on a substrate 5116, which can be attached to the wafer stage 1006 shown in
For simplicity, the aerial image 1008 and the aperture 1011 are assumed to be one-dimensional (i.e. invariant in the y-direction). One-dimensional test patterns are used for the purpose of imaging performance evaluations. In
The fact that measured image JM(x, ƒ) depends on ƒ=sin ξ has been found through intensive research by the inventor of the present invention, and constitutes theoretical foundation of the invention.
The profile of the measured image JM(x, ƒ) is changed from the aerial image I(x), because the aerial image I(x) can be influenced when the light of the aerial image transmits the slit as the aperture. Here, the mechanism of such image profile change is explained using
The aerial image 1008 on the wafer 1003 is created as a result of interference between diffraction beams 6121 captured by the projection lens 1007. In an actual exposure system, the illumination system 1004 provides illumination beams that illuminate the reticle pattern 1002 with different angles. Such illumination distribution is denoted by L(u).
In
I(x)=∫L(u)|∫−α
where αmax limits the range of diffraction beams that are captured by the projection lens 1007. Eq. (2) represents the profile of aerial image 1008.
More generally, the aperture (slit) 1011 can work as an optical device that converts the incident plane wave 7122 to the quasi-cylindrical wave 7123, and its optical properties can be described by a complex function F(α; ƒ), where α=sin θ and ƒ=sin ξ.
Using the function F(α; ƒ), it can be shown after careful analysis that the profile of the measured image 1016 in
I
M(x)=∫L(u)[∫−ƒ
where αmax restricts the range of beam directions entering the slit and ƒmax limits the range of beams captured by the detector. The numerical aperture of projection lens 1007 is given by n×αmax where n is the refractive index of a medium between the projection lens 1007 and the wafer 1003. The medium could be air or water, for example.
In a case of F(α; ƒ)=1, it is obvious that Eq. (3) is reduced to Eq. (2). In general, however, the optical properties of aperture (slit) 1011 given by F(α; ƒ) depend on α and ƒ; then the image profile given by Eq. (3) will be different from the one given by Eq. (2).
The image recovery process using the distribution of Eq. (3) is presented in
This embodiment according to the present invention is based on the following theoretical analysis conducted by the inventor of the present invention.
After careful consideration, it is shown that Eq. (3) is transformed to
I
M(x)=∫−ƒ
by interchanging the integration variables ƒ and u. Then, it is understood that the measured image 1016 (see
By assuming that the parameter ƒ is discrete, and ƒn with n: 1˜N represents the whole range of ƒ, Eq. (4) is transformed to
It is understood that Eq. (6) represents the profile of measured image 5118 in
A structure of aperture (slit) 1011 used for aerial image measurement is shown in
The optical properties F(α; ƒ) of the slit structure shown in
Here, we consider the case of K=4, with ƒ1=0.0, ƒ2=0.2, ƒ3=0.4, and ƒ4=0.6.
The optical properties of the slit for each ƒk are presented in
Measured image profiles obtained for the object pattern 1005 (see
Using K measured image data JM(x, ƒ1)˜JM(x, ƒK) together with K slit-property functions F(α; ƒ1)˜F(α; ƒK), the image recovery process illustrated by
The image recovery process is explained in detail below.
In “Step A”, L(u) and Φ(α) are obtained as a result of optimization with iteration calculations. The optimization is targeted to minimize the cost function:
ĴM(x, ƒk) is calculated using {circumflex over (L)}(u) and {circumflex over (Φ)}(α) which are intermediate states of L(u) and Φ(α), respectively, and are varied in an appropriate manner during optimization.
When the value of Eq. (7) takes its global minimum (ideally zero), the interim functions {circumflex over (L)}(u) and {circumflex over (Φ)}(α) should be equal to L(u) and Φ(α), respectively.
After determining the optimum functional form for {circumflex over (L)}(u) and {circumflex over (Φ)}(α), they are substituted to Eq. (2) in step B to obtain the profile of aerial image 5118 (see
In “Step A” of
In this embodiment, such initial state is specified by the design values for L(u) and Φ(α). As mentioned above, one of the purposes of aerial image measurement is to determine the deviation of optical characteristics from the design state. So, even though the actual forms for L(u) and Φ(α) are different from the design, it is expected that they are in the vicinity of the design state.
Herein, the initial states for L(u) and Φ(α) are represented by {circumflex over (L)}(u)ini and {circumflex over (Φ)}(α)ini, respectively. An example for the distribution of {circumflex over (L)}(u)ini is illustrated in
The magnitude and the phase of {circumflex over (Φ)}(α)ini are illustrated in
K=4 was chosen for the simplicity of explanations here. The number of K can be increased easily by repeating scanning operation with different positional setting for the detector 5114.
The above calculations can be conducted by a computer directly connected to the lithography system 5001, then the calculation results can be used for the correction of imaging performance of the lithography system. In an actual operation of lithography system 5001, it is required to check its optical performance periodically, and correct the performance if any degradation is observed.
A projection lens control unit 6202 is implemented in the projection lens 1007 to slightly modify its characteristics by, for example, slightly moving optical elements in the projection lens. Based on the results of aerial image measurement, a computer 6200 can control the illumination system control unit 6201 and/or the projection lens control unit 6202 to improve the performance of lithography system 6001.
Advanced exposure systems typically employ “immersion technology” in which the space between the bottom lens element of the projection lens 1007 and a wafer 1003 may be filled with liquid 5010 to improve resolution shown in
The first embodiment according to the present invention can be used to reconstruct the image profile (aerial image) based on the measurement result by slit scanning. This process involves an inverse problem. In the first embodiment, plural image profile data, which are distinct from each other and obtained by slit scanning, are used for the optimization calculation to solve the inverse problem. As a result, the aerial image profile can be reconstructed precisely.
An aerial image measurement described above can also be used for monitoring to compensate a lens unit, for illumination or projection, which might deteriorate with age.
In the first embodiment described above, the scanning operation needs to be repeated for K times to obtain K measured image data JM(x, ƒ1)˜JM(x, ƒK).
An apparatus 7009 for aerial image measurement is illustrated in
As a third embodiment, a pinhole-type aperture 8011 as shown in
While embodiments according to the present invention have been described with reference to exemplary embodiments, it is to be understood that the present invention is not limited to the above described embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.