This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2009-130892, filed on May 29, 2009; the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to a manufacturing method of a phase shift mask, a creating method of a mask data of a phase shift mask, and a manufacturing method of a semiconductor device.
2. Description of the Related Art
In a manufacturing process for a semiconductor device, higher resolution above a resolution limit determined from an exposure wavelength is demanded in a photolithography step as patterns become finer. To satisfy this demand, a so-called phase shift mask that increases resolution by providing a phase difference between lights transmitted through adjacent regions is proposed (see International Publication No. 06/064679, for example). An attenuated phase shift mask (AttPSM) is known as an example of the phase shift mask, which has a small optical transparency in a light shielding film, thereby making phases of transmitted lights opposite. The thickness of the light shielding film is adjusted so that a phase difference between lights transmitted through a region including the light shielding film and a region including no light shielding film, adjacent to each other on the phase shift mask, becomes 180 degrees.
An exposure technique using immersion method is developed, which applies an ArF excimer laser beam (having a central wavelength of 193 nanometers) as an exposure light to form a finer pattern. The exposure technique using immersion method enables a lithography process at an ultrahigh numerical aperture (NA), for example, with a projector lens having an NA of about 1.3. In this case, a pattern size on a photomask is equivalent to a wavelength of the exposure light. Accordingly, influences of events caused by a structure of the photomask, particularly a film thickness upon phase shift, such as a waveguide effect on the photomask and shielding of the exposure light by oblique incidence of the exposure light to the photomask become problems. An amount of phase shift on a pupil varies according to pitches or pattern dimensions of mask patterns, and therefore it is difficult to adjust focus for a plurality of mask patterns.
A manufacturing method of phase shift mask according to an embodiment of the present invention comprises: preparing a phase shift mask including a transmitting unit that transmits an exposure light and a light shielding unit that shields at least part of the exposure light, and having a plurality of mask patterns in which at least either one of pitches and pattern dimensions thereof are different, or mask data of the phase shift mask; performing an exposure experiment through the phase shift mask having a dug portion formed in a region for configuring the transmitting unit, or a lithography simulation using the mask data; obtaining an overlapped focus range in each of the plural mask patterns in a case where a result of exposure to each of the mask patterns, obtained by the exposure experiment or the lithography simulation, meets a desired dimension; and forming a dug portion with a digging depth determined at discretion based on the obtained overlapped focus range.
A creating method of mask data of phase shift mask according to an embodiment of the present invention comprises: preparing a phase shift mask including a transmitting unit that transmits an exposure light and a light shielding unit that shields at least part of the exposure light, and having a plurality of mask patterns in which at least either one of pitches and pattern dimensions thereof are different, or mask data of the phase shift mask; performing an exposure experiment through the phase shift mask having a dug portion formed in a region for configuring the transmitting unit, or a lithography simulation using the mask data; obtaining an overlapped focus range in each of the plural mask patterns in a case where a result of exposure to each of the mask patterns, obtained by the exposure experiment or the lithography simulation, meets a desired dimension; and creating mask data in a case where a dug portion with a digging depth determined at discretion based on the obtained overlapped focus range is formed.
A manufacturing method of semiconductor device according to an embodiment of the present invention comprises: forming a photosensitive film on a semiconductor substrate; applying an exposure light through a phase shift mask, to form a pattern on the photosensitive film; processing the semiconductor substrate by using the photosensitive film having the pattern formed thereon as a mask; preparing a phase shift mask including a transmitting unit that transmits an exposure light and a light shielding unit that shields at least part of the exposure light, and having a plurality of mask patterns in which at least either one of pitches and pattern dimensions thereof are different, or mask data of the phase shift mask; performing an exposure experiment through the phase shift mask having a dug portion formed in a region for configuring the transmitting unit, or a lithography simulation using the mask data; obtaining an overlapped focus range in each of the plural mask patterns in a case where a result of exposure to each of the mask patterns, obtained by the exposure experiment or the lithography simulation, meets a desired dimension; and forming a dug portion with a digging depth determined at discretion based on the obtained overlapped focus range.
Exemplary embodiments of manufacturing method of phase shift mask, creating method of mask data of phase shift mask, and manufacturing method of semiconductor device according to the present invention will be explained below in detail with reference to the accompanying drawings. The present invention is not limited to the embodiments.
The light shielding unit 14 of the phase shift mask shields most of the incident exposure light and transmits a small part, for example about 6% of the incident exposure light. The phase shift mask is an attenuated phase shift mask that inverts a phase of the transmitted light by the light shielding film 12 having a small optical transparency. The light shielding film 12 is made of molybdenum silicide, for example. A thickness of the light shielding film 12 is adjusted so that a phase difference of lights transmitted through the transmitting unit 13 and the light shielding unit 14 adjacent to each other becomes 180 degrees. Dug portions 15 are formed in the transmitting unit 13 of the transparent substrate 11. The dug portions 15 are formed by digging regions on the surface of the transparent substrate 11, in which the light shielding film 12 is formed.
Problems of a phase shift mask manufactured by a conventional manufacturing method are explained with reference to
A maximum incident angle of the exposure light incident on the phase shift mask M can be increased by increasing an NA of the projection optical system 17. However, when the incident angle of the exposure light incident on the phase shift mask M is increased, influences of events caused by a structure of the phase shift mask M, particularly a film thickness, on phase shift such as a waveguide effect of the phase shift mask M and shielding of the exposure light by a mask pattern due to oblique incidence of the exposure light become problems.
The first embodiment is characterized such that the depth of the dug portions 15 (see
At Step S2, a measurement to check focus dependencies of the mask patterns is performed. When the phase shift mask is prepared at Step S1, the focus dependencies are checked in an exposure experiment by exposure through the phase shift mask. In the exposure experiment, pattern dimensions are determined by measuring a resist pattern formed by exposure.
When the mask data for the phase shift mask is prepared at Step S1, the focus dependencies are checked in a lithography simulation. In the lithography simulation, optical image calculation or mask image observation is performed, for example. When the optical image calculation is performed, the pattern dimensions are determined by estimating a resist pattern from an optical image. A pattern dimension, a positional relation, or the like in a desired design is used as data inputted for the simulation, for example. When the mask image observation is performed, the mask pattern dimensions are determined by estimating a resist pattern from a result of observation by the AIMS, for example. The pattern dimension can be determined by performing at least one of the exposure experiment, the optical image calculation, and the mask image observation. The pattern dimension can be determined by performing a combination thereof.
At Step S3, at least two of the plural mask patterns are selected as selection mask patterns. Mask patterns that provide smallest overlapped focus ranges when a result of the exposure in the exposure experiment or the lithography simulation before forming dug portions meets a desired pattern dimension are selected as the selection mask patterns.
It is assumed for example that the measurement result as shown in
In the group A, however, curves are shallower than those of other groups, and variations in the CD caused by changes in the focus are relatively small. Accordingly, even when the center position of the focus is deviated, margins to other patterns can be obtained relatively easily. Thus, one mask pattern from each of the groups B and D, in which the variations in the CD with respect to the focus are large and the overlapped focus range when the desired pattern dimension is met is the smallest, is selected as the selection mask patterns.
When the phase shift mask is prepared at Step S1, dug portions are formed in regions that configure a transmitting unit of a testing substrate at Step S4. At Step S5, a measurement to check the focus dependencies of the selection mask patterns is performed. At Step S6, it is determined whether the depth of the dug portions thus formed reaches an upper limit.
When the dug portions 22 are formed at first Step S4 and the measurement at Step S5 is finished, the digging depth d is lower than the upper limit (No at Step S6), and then the process returns to Step S4 to perform second digging. The processes from Steps S4 to S6 are repeated until the digging depth d of the dug portions 22 reaches the upper limit. The upper limit of the digging depth d can have an arbitrary value and can be properly set. It is only necessary that the dug portions 22 be formed at least in regions including the selection mask patterns at Step S4, and the present invention is not limited to the case where the dug portions 22 are formed across the testing substrate 21.
When the digging depth d of the dug portions 22 reaches the upper limit (YES at Step S6), an optimum value of the digging depth d is determined. Among measurement results obtained each time the digging depth d is changed in a stepwise manner, a digging depth d obtained when an overlapped focus range when the desired pattern dimension is met is the largest is determined as the optimum value (Step S7). The process for determining the optimum value of the digging depth d is then ended. The phase shift mask is manufactured by forming a film of a light shielding material on the transparent substrate 11 as a material substrate, patterning the film, and then forming the dug portions 15 with the optimum digging depth determined in the above procedure.
Also when the lithography simulation is performed, a digging depth at the time of a largest overlapped focus range is determined as the optimum value based on exposure results obtained each time a digging depth of the phase shift mask is changed. Data of a mask including the dug portions with the optimum digging depth is created, and the phase shift mask is manufactured based on the created mask data. When the optimum value of the digging depth is determined by the lithography simulation, an amount of variations in the digging depth d can be set according to optimization algorithm. Accordingly, the amount of variations in the digging depth d is not limited to the one in the case where the digging depth is changed in a stepwise manner.
In the first embodiment, the digging depth is changed until when the digging depth reaches the upper limit, and a digging depth that provides a largest focus range is adopted. However, the present invention is not limited thereto. For example, a digging depth that provides a largest overlapped focus range during an arbitrary number of measurements to obtain a focus range can be adopted. Alternatively, a digging depth that provide an overlapped focus range meeting an admissibility condition during an arbitrary number of measurements can be adopted. When an overlapped focus range even in a case where one measurement is performed to set a digging depth is larger than that in a case where no dug portion is formed, such a digging depth can be adopted. In the first embodiment, at least dug portions with a digging depth determined at discretion according to the obtained overlapped focus range are formed, or mask data at the formation of the dug portions is created.
It is assumed that a center position of the focus in the mask pattern 1 is 25 nanometers and a center position of the focus in the mask pattern 2 is 14.29 nanometers when no dug portion is formed. In this case, a difference in the center position of the focus between the mask patterns 1 and 2 is 10.71 nanometers.
It is assumed that the center position of the focus in the mask pattern 1 is 0 nanometer and the center position of the focus in the mask pattern 2 is 4 nanometers when the digging is performed until the digging depth d reaches 5 nanometers. In this case, the difference in the center position of the focus between the mask patterns 1 and 2 is 4 nanometers.
It is assumed that the center position of the focus in the mask pattern 1 is −25.0 nanometers and the center position of the focus in the mask pattern 2 is −6.25 nanometers when the digging is performed until the digging depth d reaches 10 nanometers. In this case, the difference in the center position of the focus between the mask patterns 1 and 2 is 18.75 nanometers.
A largest overlapped focus range between the mask patterns 1 and 2 at the desired pattern dimension is obtained when the difference in the center position of the focus is the smallest. From the above results, the difference in the center position of the focus is the smallest when the digging depth d is 5 nanometers. When the digging depth d is 5 nanometers, the overlapped focus range between the mask patterns 1 and 2 at the desired pattern dimension is the largest. Therefore, when the dug portions 15 with the digging depth 5 of 5 nanometers are formed in the phase shift mask, defocus can be adjusted so that the influences of the waveguide effects in the mask patterns 1 and 2 become similar to each other.
When the mask patterns that provide the smallest overlapped focus range at the desired pattern dimension are selected as the selection mask patterns from the plural mask patterns to obtain an optimum value of the digging depth d, defocus adjustment that produces similar waveguide effects in all the plural mask patterns can be performed. In this way, the defocus resulting from the structure of the photomask can be reduced in the plural mask patterns. When the focus ranges are kept within a focus margin of the exposure device to meet the desired pattern dimensions of all the plural mask patterns, all the mask patterns can be resolved with a satisfactory margin.
A method of manufacturing a semiconductor device according to the first embodiment is then explained. The phase shift mask manufactured by the above steps is positioned in an optical path of the exposure device. A semiconductor substrate having a photosensitive film formed thereon is placed on a wafer stage and irradiated with an exposure light through the phase shift mask. The exposure through the phase shift mask can reduce defocus in the plural mask patterns, and enables to project the patterns at high resolution and with reliability. Further, a photosensitive film pattern is formed by developing the photosensitive film exposed in the manner mentioned above, and the semiconductor substrate is etched by using the photosensitive film pattern as a mask. The semiconductor device can be manufactured in this way. The method of manufacturing the phase shift mask described in the first embodiment can be applied to manufacture a phase shift mask other than the attenuated phase shift mask.
|k|<0.1 (1)
The transparent member 25 is a member that satisfies the expression (1), for example, a transparent resin member. It is preferable that the extinction coefficient k be closer to zero because influences on transmittance can be reduced. With the transparent member 25, the amount of phase shift of the exposure light due to the waveguide effect is cancelled near the plural mask patterns when the exposure light is applied through the phase shift mask. Accordingly, defocus in the plural mask patterns can be reduced and the patterns can be projected at high resolution and with reliability.
In a phase shift mask shown in
In a phase shift mask shown in
In a phase shift mask shown in
When the refractive index of the transparent substrate 11 is adjusted by applying any one of the three manners as shown in
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
Number | Date | Country | Kind |
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2009-130892 | May 2009 | JP | national |