This application relates to and claims priority from Japanese Patent Application No. 2003-198844, filed on Jul. 18, 2003, the entire disclosure of which is incorporated herein by reference.
1. Field of the Invention
The present invention relates to a method of setting optimal etching parameters in a semiconductor manufacturing process and a system therefor. More specifically, the present invention relates to a system that picks up an image of a pattern formed on a wafer, represents workmanship of the pattern quantitatively, performs etching parameter correction for reducing an amount of deviation between a quantitative value of the workmanship and a target etching pattern, and realizes setting for optimal etching parameters, and a performance evaluation system that evaluates performance of etching.
2. Description of the Related Art
A conventional method of setting etching parameters (a gas flowrate, a pressure, a voltage, electric power, temperature, time, etc.) for an etching process in semiconductor manufacturing will be explained with reference to
Instep 201, in order to perform desired etching, a person determines initial values of etching parameters, which are suitable for a quality of material of an etching object and an etching shape, with a help of experiences in the past and intuition on the basis of characteristics, which have been obtained through experiments, concerning the quality of material of the etching object and characteristics of an etching apparatus being used.
In step 202, the person performs etching with the etching parameters determined in step 201. In step 203, the person observes a pattern on a wafer, which is formed by the etching, with a scanning electron microscope (SEM) or the like to measure the etching pattern. In step 204, the person judges manually whether desired etching performance is obtained on the basis of a measurement value obtained in step 203. If it can be judged that a result of the etching is satisfactory, the person determines etching parameters.
If it is judged that the result of the etching is unsatisfactory, in step 205, the person performs correction for the etching parameters, which brings etching performance close to the desired etching performance, on the basis of experiences in the past. Then, the person returns to step 202 and performs etching again with etching parameters set anew.
According the method described above, the person determines etching parameters most suitable for obtaining the desired etching performance.
In the above-mentioned conventional technique, the person determines initial values and corrected values of etching parameters according to experiences and intuition to derive optimal etching parameters. However, such manual setting for etching parameters is inefficient because the manual setting takes time until optimal setting for etching parameters is obtained. In addition, it is possible that set values contain individual differences.
Thus, the present invention has been devised in view of these problems, and it is an object of the present invention to provide a method of setting optimal etching parameters for performing desired etching and a system therefor.
The present invention provides a method of setting parameters for etching, which includes: acquiring an electron beam image of a pattern formed on a surface of a wafer treated by an etching apparatus; processing the acquired electron beam image of the pattern formed on the surface of the wafer to judge workmanship of the pattern; presenting a result of judging the workmanship to a user; calculating corrected values of etching parameters for the etching apparatus on the basis of the result of judging the workmanship; and sending the calculated corrected value to the etching apparatus, and a system for the method.
In addition, the present invention provides a method of setting parameters for etching, which includes: acquiring an electron beam image of a pattern formed on a surface of a wafer treated by an etching apparatus; processing the acquired electron beam image of the pattern formed on the surface of the wafer to extract a characteristic amount of the pattern; comparing the extracted characteristic amount of the pattern with data set in advance to judge workmanship of the pattern; presenting a result of judging the workmanship to a user; and calculating corrected values of etching parameters for the etching apparatus on the basis of the result of judging the workmanship, and a system for the method.
These and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
In the accompanying drawings:
Embodiments of the present invention will be hereinafter explained with reference to the accompanying drawings.
Outline
Details of the respective steps will be hereinafter explained.
(1) Derivation of an Optimal Parameter Calculation Model (Step 301 in
A method of deriving an optimal parameter calculation model will be explained. In this embodiment, a response surface model, which is generally used for statistical processing, is used as a modeling method for an optimal parameter calculation model.
First, in step 901, an evaluation experiment using, for example, a Taguchi method is performed to find parameters, which affect in-plane evenness in an etching process, among the etching parameters. In step 902, the etching parameters affecting in-plane evenness are excluded from controllable parameters (e.g., d, e, and f). These parameters are always fixed as fixed etching parameters, whereby evenness on a wafer is prevented from being ruined. In step 903, experiment data necessary for the derivation of an optimal parameter calculation model (experiment data with the etching parameters a, b, and c as inputs and the etching performance quantitative values A, B, and C as outputs) is acquired using, for example, an experimental design method. In step 904, an optimal parameter calculation model using a response curve is created. An optimal parameter calculation model to be generated by the response surface method is a multidimensional model with the items of the target etching performance quantitative value A, B, C as inputs and the etching parameters a, b, and c as outputs.
(2) Setting for an Etching Target Value (Step 302 in
A desired etching target value is set. For example, in the case in which an etching pattern is a contact hole, a hole diameter, hole roundness, a white band portion width in an image photographed by a scanning electron microscope, roughness of a white band portion contour, roughness of a hole bottom pattern, a hole depth, an inclination angle of a hole wall, and the like are target values.
(3) Etching Parameter Setting Using the Optimal Parameter Calculation Model
The etching target value is inputted to the optimal parameter calculation model prepared in advance in step 301 to calculate initial etching parameters.
(4) Acquisition of an SEM Image (step 305 in
An image of an etching pattern is picked up by a scanning electron microscope (SEM).
The secondary electron generated from the wafer 710 is deflected by the E×B deflector 705 and detected by a secondary electron detector 707. A two-dimensional electron beam image is obtained by two-dimensional scanning of the electron beam by the beam deflector 704 or repeated scanning in an X direction of the electron beam by the beam deflector and detection of electrons that are generated from the wafer 710 in synchronization with continuous movement in a Y direction of the wafer 710 by a stage 711.
A signal detected by the secondary electron detector 707 is converted into a digital signal by an A/D converter 708 and sent to an image processing unit 720. The image processing unit 720 has an image memory for temporarily storing a digital image and a CPU that performs calculation for a line profile and a characteristic amount from an image on the image memory. In addition, the image processing unit 720 has a storage medium 721 for saving the characteristic amount calculated from a result of image processing as a database and a display 722 that displays the image and the processing result.
In this embodiment, prior to carrying in a product wafer, a correspondence model of etching parameters, which are adjusted to obtain a desired etching pattern, and a characteristic amount, which is desired from an electron image of an etching pattern that is formed when the etching parameters are changed, (hereinafter referred to as an optimal parameter calculation model) is derived by a preliminary experiment and saved in a storage 5b shown in
As the scanning electron microscope to be used, a scanning electron microscope that picks up a tilt image may be used in addition to the one that picks up a top-down view image. As means for picking up a tilt image, a system for inclining a table 711 on which the wafer 710 is mounted or a system for controlling a trajectory of a primary electron beam with an electro-optic system of the scanning electron microscope (SEM) to make the primary electron beam incident on a wafer surface from an inclined direction maybe adopted. In both the systems, a tilt angle (an inclination angle of a primary electron beam with respect to a normal direction of the wafer surface) is set between 0° to about 15° to obtain a tilt image.
Here, the structure show in
(5) Performance Quantization (Step 306 in
As an example of a characteristic amount derived from an electron beam image of an etching pattern (a line patter, a hole pattern, etc.), an etching performance quantitative value is proposed. The etching performance quantitative value is obtained by picking up an image of an object generated by etching with an SEM and applying image processing to the picked-up image. For example, in the case in which an object of formation on a wafer to be observed is a line pattern, characteristic amounts (a line width 401, line edge roughness 402, a white band width 403, etc.) are represented quantitatively by image processing as shown in
In addition, in the case in which an object of formation on a wafer is a hole pattern, characteristic amounts (a hole diameter 410, hole roundness 411, a white band portion width 412, roughness of a white portion contour line 413, roughness of a contact hole bottom pattern 414, etc.) are represented quantitatively by image processing as shown in
(6) Judgment (Step 307 in
It is judged using threshold processing or the like whether or not the performance quantitative value calculated in step 306 is within a fixed allowable range with respect to the etching target value set in step 302. In addition, an amount of deviation of an optimal etching parameter from a target value is calculated.
(7) Etching Parameter Correction Using a Minimum Parameter Calculation Model
In
As described above, etching parameters most suitable for realizing desired etching are derived on the basis of the optimal parameter calculation model. In the above-mentioned method, etching parameters are changed finely. However, etching parameters leading to an optimal etching performance value, which are calculated from the model, may be used as the next etching parameters directly.
(8) GUI (Step 306 and Step 307 in
An etching performance quantitative value after etching calculated in step 306 is displayed on a GUI shown in
In addition, if a result of the quality judgment for etching calculated in step 307 indicates defectiveness, a result of judging a cause of the defectiveness (etching stop, occurrence of deposition, etc.) is also displayed (804).
This embodiment is a system that automatically derives etching parameters most suitable for realizing target etching as in the above-mentioned method.
System for Calculating Optimal Etching Parameters at the Time of Mass Production
This embodiment is an example concerning optimization for etching parameters in an etching process at the time of mass production in semiconductor manufacturing.
The optimal parameter calculation model is used again after the correction to calculate an optimal recipe from the target value. However, in the case in which values of etching parameters calculated from the corrected model are outside a range of values that can be set by the etching apparatus, an alarm is notified for etching treatment for a second wafer to prevent the etching treatment from being performed. Consequently, when abnormality has occurred in the apparatus, a large number of defects can be prevented from being caused. In addition, this alarm can also be used for judgment on execution of maintenance processing called total cleaning. According to the above-mentioned method, optimal etching parameters are set in an etching process at the time of mass production.
A processing flow shown in
If it is judged in step 606 that the etching performance value does not satisfy the etching target value, in step 608, an etching parameter corrected value for bringing an etching result close to the target etching value is calculated, and a result of the calculation is fed back to step 602 for setting optimal etching parameters to set optimal etching parameters. Then, etching is performed again with an etching recipe based on the etching parameters set anew.
The present invention makes it possible to calculate optimal etching parameters for obtaining desired etching performance in an etching process in semiconductor manufacturing. In addition, the present invention makes it possible to control influence of disturbance due to continuous operation of an apparatus to continue etching with optimal parameters at the time of mass production in an etching process.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefor to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Number | Date | Country | Kind |
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2003-198844 | Jul 2003 | JP | national |