This application claims priority under 35 U.S.C. §119 on Patent Application No. 2004-69585 filed in Japan on Mar. 11, 2004, the entire contents of which are hereby incorporated by reference.
The present invention relates to a method for forming a mask pattern used for fabrication of semiconductor integrated circuits with high accuracy relative to a layout pattern as design values for the semiconductor integrated circuits.
In conventional mask pattern correction methods, corrected are a defocus occurring in an exposure process due to a difference in the height of an underlying layer and a dimension error occurring due to the proximity effect of a corrected pattern (Japanese Laid-Open Patent Publication No. 2002-333701 (page 3, paragraph 0016,
In other methods, correction using optical simulation results of layout design pattern data is adopted (Japanese Laid-Open Patent Publication No. 2002-174890 (page 2, paragraph 0008,
In the prior art technologies, with the aim of replicating a layout pattern as faithfully as possible, attention is focused on correction technology for correcting a mask pattern. The correction technology is known to include an error due to its theoretical limit. However, no verification has yet been established for circuit operation associated with deformation of a layout pattern due to this error. For example, when the absolute value of a fabrication variation is ±5 nm, the error is ±1.43% in the case of a minimum feature size of 350 mm, but it is ±5% in the case of a minimum feature size of 100 nm. In the latter case, therefore, the relative variation increases. No verification has conventionally been allowed for whether or not this potential variation error is permissible in the circuit design.
A problem that will occur in the future with achievement of a finer fabrication process and a potential problem that may occur in the present situation cannot be verified even based on layout data as long as simulation is made within the normal fabrication variation range. For example, although no problem occurs in fabrication in the case of a minimum feature size of 350 nm, a problem may occur in the case of a minimum feature size of 250 nm. To find out this problem under the fabrication technology for the minimum feature size of 350 mm, layout data for the minimum feature size of 350 nm may be scaled down to 71%, and fabrication may be made under the fabrication technology for the minimum feature size 350 nm. A problem that may possibly occur in the case of a minimum feature size of 250 nm can then be detected. The problem detected in the above manner is found to be a potential point of problem (point having the possibility of becoming a problem and coming to the surface in the future) because this indicates that the fabrication technology has no allowance at this point of problem even in the case of a minimum feature size of 350 nm.
In prediction of the yield in fabrication of semiconductor integrated circuits, the predicted value obtained based on layout data is different from the actual yield value because no consideration is given to the finished shape of a circuit pattern on a silicon wafer. The predicted value therefore includes an error. For example, a layout pattern formed on a silicon wafer is susceptible to the exposure dose within the range of a fabrication variation, defocus and steps computed from the layout pattern. The resultant layout pattern includes portions locally heavy or thin sporadically compared with the original layout pattern. Therefore, the sensitivity to an open circuit (cutting of the pattern) and a short circuit (contacting of adjacent lines of the pattern) tends to be low in the prediction of the yield of the semiconductor integrated circuits.
The method of the present invention includes the steps of: simulating deformation of a layout pattern to be formed on a silicon wafer; extracting a circuit configuration formed on the silicon wafer from the deformed layout pattern; and simulating operation of the extracted circuit, whereby the degree of deformation of the layout pattern is computed based on the exposure dose within the range of a fabrication variation, defocus and steps computed from the layout pattern, a circuit configuration is extracted from the deformed layout pattern, and the resultant circuit is simulated, to thereby verify an effect of the deformation of the layout pattern on the circuit operation.
Alternatively, the method of the present invention includes the steps of: shrinking a layout pattern at a given rate; and simulating deformation of the shrunk layout pattern to be formed on a silicon wafer, whereby the degree of deformation of the layout pattern is computed based on the exposure dose within the range of a fabrication variation, defocus and steps computed from the layout pattern, to thereby verify an effect of the deformation of the shrunk layout pattern on the circuit operation.
Alternatively, the method of the present invention includes the steps of: simulating deformation of a layout pattern to be formed on a silicon wafer; and simulating an irregular problem occurring in a fabrication process, whereby the degree of deformation of the layout pattern is computed based on the exposure dose within the range of a fabrication variation, defocus and steps computed from the layout pattern, and degradation in yield due to an irregular problem in a fabrication process is detected, to thereby verify an effect of the deformation of the layout pattern on the circuit operation.
According to the present invention, a problem in circuit operation due to deformation of a layout pattern to be formed on a wafer can be detected. Thus, not the entire mask pattern, but only a portion of the mask pattern that is to cause a problem in circuit operation can be properly corrected. If such correction is not allowed, it is possible to return to circuit design and change the circuit configuration to enable normal operation.
Also, by shrinking a layout pattern at a given rate, prior examination can be made on a problem that will occur in design of next-generation semiconductor integrated circuits. In addition, a currently potential defective portion can be verified.
Moreover, by computing the yield based on deformation of a layout pattern to be formed on a wafer, the actual yield can be computed accurately, and thus proper correction can be made for a portion of a mask pattern that is to cause a problem. If such correction is not allowed, it is possible to return to layout design and change the layout pattern to enable normal operation.
The layout data verification method, the mask pattern correction method and the circuit operation verification method of the present invention include a photolithography simulation step, a silicon wafer step simulation step, a circuit information extraction step and a yield calculation step. These methods are useful for verification of a mask pattern and other uses. Using the verification results, also, these methods are applicable to prediction of the yield in fabrication of semiconductor integrated circuits and other uses. They are also applicable to detection of a potential problem factor.
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.
<Silicon Wafer Surface Step Simulation Step ST100>
First, the entire mask pattern is divided into regions in a grid shape (ST101). In this region division, each of the divided mask pattern regions is arranged to overlap its adjacent mask pattern regions by a given amount so that in photolithography simulation to follow for each layer of each of the mask pattern regions, a layout pattern is obtained as a result of simulation performed correctly even to the boundaries of each region.
The area factor of each layer is then calculated for each layout pattern region (ST102). The area factor of each layer is multiplied by a coefficient related to the height of the layer, to obtain the height of each layer of each layout pattern region, and then the height of a silicon wafer in each photolithography process can be obtained as the sum of the heights of all layers.
The difference (defocus) of the resultant height from the focus setting in the photolithography simulation is then determined as the silicon wafer surface step (ST103).
<Exposure Dose Determination Step ST110>
In the exposure dose determination step ST110, the step width is determined according to the required analysis accuracy within the range of a variation in exposure dose arising in the fabrication process in fabrication of semiconductor integrated circuits, and the exposure dose is determined to be changed so that the range of the variation from its lower to upper limits is scanned with the step width.
<Photolithography Simulation Step ST120>
In the photolithography simulation step ST120, simulation is performed to replicate the photolithography process in fabrication of semiconductor integrated circuits on a computer based on the defocus value determined in the silicon wafer surface step simulation step ST100 and the exposure dose for each step width determined in the exposure dose determination step ST110. As a result of the simulation, a layout pattern shape (wafer image) formed on a silicon wafer is obtained.
<Wafer Image Verification Step ST130>
In the wafer image verification step ST130, pattern comparison is made between the layout pattern obtained as a result of the photolithography simulation and the design layout pattern.
<Fault Point Detection Step ST140>
In the final fault point detection step ST140, when a short circuit or a break is found in the wafer image verification step ST130, such a point is naturally detected as a fault point. In addition, an allowance is set so that a point having a high possibility of causing a short circuit or a break although not yet causing such a trouble (for example, solid-line patterns (b) in
<Exposure Dose Determination Step ST200>
<Photolithography Simulation Step ST210>
<Circuit Information Extraction Step ST220>
In this simplification, the layout pattern shape formed on a silicon wafer is made to approximate the original layout data as shown in
Information on the semiconductor integrated circuit is then extracted from the simplified layout pattern (ST223). Examples of information extracted in this step include the gate length and gate width of transistor elements and the width of interconnections for connection between semiconductor elements. Based on such information, information on the semiconductor integrated circuit is reconstructed.
<Fault Point Detection Step ST230
In the fault point detection step ST230, circuit operation is simulated based on the information on the semiconductor integrated circuit, to locate a defective circuit.
Approximate data 1001 to the layout pattern shape formed on a silicon wafer, extracted in a circuit information extraction step ST301 (processing in this step is the same as that described in Embodiment 2) is given to a critical area computation step ST302.
In the critical area computation step ST302, the layout data 1001 is divided into line regions and space regions by graphic logical operation. The line regions are then classified into several types according to the line width by resizing and graphic logical operation, and the sum of critical areas for each type is determined. Likewise, the space regions are classified into several types according to the space shape, and the sum of critical areas for each type is determined. In this way, a critical area 1002 of an image formed on a silicon wafer is computed.
In a yield prediction step ST303, the yield of the image formed on a silicon wafer can be predicted from expression 1 to be described later, permitting random defect prediction for both open circuit and short circuit.
An example of prediction of the yield in fabrication will be described. Some methods have been proposed for yield prediction, including a method using a defect distribution curve and the critical area in which a defect actually causes a failure for the yield prediction (ISSM 1997, 0.25 um Integrated Circuit Yield Model Design and Validation).
The overall yield of a process is generally represented by the product of the systematic yield (YS) determined according to the system and the yield (YR) determined with a random defect.
The yield YR determined with a random defect is represented by the expression 1 below according to a Poisson distribution model, for example.
YR=exp(−DD*Ac) Expression 1
where DD is the number of defects per unit critical area and Ac is a critical area.
The critical area as used herein refers to the total sum of areas in a chip that may actually be impaired due to existence of defects.
The idea of the critical area will be described in relation to a short circuit between interconnections with reference to
The critical area can also be computed in relation to open interconnections in a similar manner.
Thus, the yield prediction for the pattern formed on a silicon wafer can be performed by computing the critical area based on the data obtained after the extraction of the circuit information from the simulation result and adopting the model of the expression 1.
Referring to
In an exposure dose determination step ST410, the step width is determined according to the required analysis accuracy within the range of a variation in exposure dose arising in the fabrication process in fabrication of semiconductor integrated circuits, and the exposure dose is determined to be changed so that the range of the variation from its lower to upper limits is scanned with the step width.
In a photolithography simulation step ST420, simulation is performed to replicate the photolithography process in fabrication of semiconductor integrated circuits on a computer based on the exposure dose for each step width determined in the exposure dose determination step ST410. As a result of the simulation, a layout pattern shape formed on a silicon wafer is obtained.
In a fault point detection step ST430, circuit operation is simulated based on the information on the semiconductor integrated circuit, to locate a defective circuit.
While the present invention has been described in preferred embodiments, it will be apparent to those skilled in the art that the disclosed invention may be modified in numerous ways and may assume many embodiments other than that specifically set out and described above. Accordingly, it is intended by the appended claims to cover all modifications of the invention which fall within the true spirit and scope of the invention.
Number | Date | Country | Kind |
---|---|---|---|
2004-069585 | Mar 2004 | JP | national |