The technical field generally relates to methods of controlling the focus of ultraviolet (UV) light from a lithographic imaging system, apparatuses for forming an integrated circuit that employ the method, and controllers programmed to control the focus of the ultraviolet light. More particularly, the invention relates to methods, apparatuses, and controllers that employ test patterns to adjust the focus of ultraviolet light from the lithographic imaging system.
Focus control is an important consideration in lithography techniques to ensure proper pattern formation in semiconductor devices. Focus control generally involves focus monitoring to provide feedback for adjusting the focus of UV light from a lithographic imaging system on the semiconductor device. The lithographic imaging system generally includes a light source, a collector (also known as a condenser lens system), a lithography mask (also known as a reticle), and an objective lens (also known as an imaging or reduction lens). In lithography techniques that involve extremely small scale of illuminated patterns, such as extreme ultraviolet (EUV) lithography, focus control is often challenging. Focus control is primarily dictated by the critical dimensions of the pattern as well as the thicknesses of the resist films that are employed during patterning, and focus control and overlay budgets in EUV lithography are also generally interdependent. As pattern critical dimensions and layer thicknesses decrease, focus control must also become more precise and accurate. Additionally, EUV lithography generally involves illumination of a lithography mask at an off-incidence angle. Due to the off-incidence angle, the best focus of UV light from the lithographic imaging system will vary depending on the size and pitch of the pattern being printed and the location of the pattern within an exposure field. As such, the best focus is variable across the exposure field.
Conventional focus monitoring techniques generally employ a metrology technique called scatterometry whereby a measured change in sidewall angle within patterns in a photoresist can be correlated to the focus of the UV light that is employed for pattern formation. However, conventional scatterometry techniques are sensitive to thickness and film properties of the photoresist. In particular, as the layer thicknesses of the photoresist decrease, scatterometry becomes less effective for focus monitoring because the measurement of sidewall angle becomes more difficult.
Phase shift focus monitoring is another conventional technique that employs a phase grating structure to monitor the focus of the light that is employed for pattern formation. The phase grating structure is a photomask that generally includes a box-in-box pattern, containing an inner nested box structure and an outer nested box structure. Using the phase grating structure, a shift in focus of the UV light manifests as an equal and opposite shift in the resulting inner and outer box patterns formed in a photoresist. However, the phase shift focus monitor does not provide adequate sensitivity for EUV lithography and is difficult to implement due to the stringent requirements that must be met during its fabrication.
Accordingly, it is desirable to provide improved methods of monitoring the focus of UV light from a lithographic imaging system, especially in lithography techniques such as EUV lithography, with the improved methods providing adequate sensitivity to changes in focus and with the improved methods not dependent on the thickness of the photoresist employed during lithography. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background.
Methods and controllers for controlling the focus of ultraviolet light produced by a lithographic imaging system, and apparatuses for forming an integrated circuit employing the same are provided. In an embodiment, a method for controlling the focus of ultraviolet light produced by a lithographic imaging system includes providing a wafer having a resist film disposed thereon. The resist film is patterned through illumination of a lithography mask with ultraviolet light at an off-normal incidence angle with a first test pattern formed at a first pitch and a second test pattern formed at a second pitch different from the first pitch. Non-telecentricity induced shift of the first test pattern and the second test pattern is measured to produce relative shift data using a measurement device. Focus of the ultraviolet light is adjusted based upon comparison of the relative shift data to a pre-determined correlation between the non-telecentricity induced shift of the first test pattern and the second test pattern as a function of focus error.
In another embodiment, an apparatus for forming an integrated circuit includes a lithographic imaging system, a controller, and a measurement device. The lithographic imaging system is configured to pattern a resist film on a wafer through illumination of a lithography mask at an off-normal incidence angle. The controller is programmed to control focus of ultraviolet light produced by the lithographic imaging system. The controller is programmed with instructions to pattern the resist film on the wafer using the ultraviolet light produced by the lithographic imaging system through illumination of the lithography mask at the off-normal incidence angle with a first test pattern formed at a first pitch and a second test pattern formed at a second pitch different from the first pitch, analyze relative shift data obtained from measuring non-telecentricity induced shift of the first test pattern and the second test pattern, and adjust the focus of the ultraviolet light based upon a comparison of the relative shift data to a pre-determined correlation between the non-telecentricity induced shift of the first test pattern and the second test pattern as a function of focus error. The measurement device is configured to measure the non-telecentricity induced shift of the first test pattern and the second test pattern to produce the relative shift data.
In another embodiment, a controller is programmed to control focus of ultraviolet light produced by a lithographic imaging system. The controller is programmed with instructions to pattern a resist film on a wafer using the ultraviolet light produced by the lithographic imaging system through illumination of a lithography mask at an off-normal incidence angle with a first test pattern formed at a first pitch and a second test pattern formed at a second pitch different from the first pitch, analyze relative shift data obtained from measuring non-telecentricity induced shift of the first test pattern and the second test pattern, and adjust focus of the ultraviolet light based upon comparison of the relative shift data to a pre-determined correlation between the non-telecentricity induced shift of the first test pattern and the second test pattern as a function of focus error.
The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
Methods of controlling focus of ultraviolet (UV) light produced by a lithographic imaging system, apparatuses for forming an integrated circuit employing the method, and controllers programmed to control focus of UV light are provided herein. The methods of monitoring focus of the UV light are particularly suited for lithography techniques that involve extremely small scale of illuminated patterns, such as extreme ultraviolet (EUV) lithography that illuminates a lithography mask at an off-normal incidence angle, and the methods provide adequate sensitivity to changes in focus and are not dependent on a thickness of the photoresist employed during lithography. In particular, non-telecentricity is a recognized phenomenon that impacts printing performance in many photolithography techniques, especially lithography techniques that illuminate a lithography mask at an off-normal incidence angle. The non-telecentricity phenomenon occurs when the UV light is out of focus due to oblique illumination of the lithography mask and off-axis reflection of light rays from different vertical positions of the lithography mask. The non-telecentricity phenomenon results in shift and bias of the patterned features on the wafer up to several nanometers with respect to their target dimension. Such shift in the patterned features may be referred to as a non-telecentricity induced shift. In accordance with the methods, apparatuses, and controllers described herein, non-telecentricity induced shift of a first test pattern and a second test pattern having different pitches is measured, and such measurement is employed in a comparison to a pre-determined correlation of non-telecentricity induced shift of the first test pattern and the second test pattern as a function of focus error. Because non-telecentricity shift varies for printed patterns having different pitches, differences in non-telecentricity induced shift in the first test pattern and the second test pattern may be employed to provide a direct correlation to focus error. Based upon the pre-determined correlation of non-telecentricity induced shift of a given first test pattern and second test pattern, focus error can be determined for first test patterns and second test patterns formed on wafers during integrated circuit fabrication, thereby allowing focus error to be expediently and accurately determined on product wafers independent of photoresist thickness.
An exemplary embodiment of an apparatus 10 for forming an integrated circuit will now be described with reference to
As shown in
Referring to
The apparatus 10 further includes a measurement device 40 that is configured to measure the non-telecentricity induced shift of the first test pattern 36 and the second test pattern 38 to produce the relative shift data. Measurement of the non-telecentricity induced shift involves measurement of a spacing between features on the nanometer scale, and suitable measurement devices 40 include those capable of measurements on the Angstrom scale. Examples of suitable measurement devices 40 include, but are not limited to, those chosen from a scanning electron micrograph device, an overlay measurement device, or a scatterometry overlay metrology device. It is to be appreciated that certain configurations of the first test pattern 36 and the second test pattern 38 may be desirable for certain measurement devices 40 as appreciated by those of skill in the art.
A method of controlling the focus of ultraviolet light produced by a lithographic imaging system, such as the lithographic imaging system 18 of the apparatus 10 shown in
The resist film is patterned through illumination of the lithography mask 20 at an off-normal incidence angle, with the first test pattern 36 formed at a first pitch and the second test pattern 38 formed at a second pitch different from the first pitch. For example,
For purposes of determining focus error, a non-telecentricity induced shift of the first test pattern 36 and the second test pattern 38 is measured to produce relative shift data using, e.g., the measurement device 40 shown in
The relative data shift is compared to a pre-determined correlation between non-telecentricity induced shift of the first test pattern 36 and the second test pattern 38 as a function of focus error, thereby enabling focus error to be determined based upon the relative shift data measured for the particular first measurement 42 and the second measurement 44. For example, to generate the data in the graph of
In various embodiments, relative shift data is produced through other measurements of non-telecentricity-induced shift between the first test pattern and the second test pattern. For example, instead of measuring and comparing the shift of features within the respective test patterns, other shift comparisons include shift between a feature of the first test pattern and a feature of the second test pattern at one location and between another feature of the first test pattern and another feature of the second test pattern at another location, shift between respective features of the first test pattern and the second test pattern and a common reference feature, or shift between a feature of the first test pattern and an overlaid reference feature in a first region and a feature of the second test pattern and an overlaid reference feature in a second region, where the reference features in the first region and the second region are formed at the same pitch.
Various relative configurations of the first test pattern and the second test pattern are possible depending upon the particular shift comparisons that are measured. In an embodiment and referring to
The non-telecentricity induced shift of the first test pattern and the second test pattern may be measured between fabrication stages during integrated circuit formation on the wafer. For example, referring again to
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.