This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2005-259162, filed on Sep. 7, 2005, the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates generally to pattern inspection of objects to be tested such as reticles, and more particularly to a method and apparatus for pattern inspection of an object being tested for use in the manufacture of semiconductor devices and liquid crystal display panels or the like. This invention also relates to reticles as pattern-inspected thereby.
2. Description of the Related Art
In large-scale integrated (LSI) circuit fabrication processes, optical reduction exposure equipment (stepper) for the circuit pattern transfer use is typically designed to employ as its original or master plate a reticle (photomask) with a circuit pattern being formed and magnified by a degree of four to five times. Completeness requirements for this reticle—that is, demands for pattern accuracy, zero defects, shorter inspection time periods and others—are becoming higher year by year. In recent years, the quest for ultra-fine fabrication and higher integration results in the pattern transfer being performed at levels in close proximity to the resolution limit of the stepper. This causes high-accuracy reticles to be the key focus in semiconductor device microfabrication processes. In particular, it is inevitable to enhance the performance of pattern inspection apparatus operative to detect defects of ultrafine patterns. Enhancing the pattern inspection apparatus performance is a must to shorten development periods of highly advanced or “leading-edge” semiconductor devices while improving production yields thereof. In this regard, a known technique for performing pattern inspection by setting up the test precision in units of reticle patterns is disclosed, for example, in JP-A-2004-191957.
It is therefore an object of the present invention to provide an approach to performing appropriate inspection by selecting a pattern comparison technique in conformity with the pattern feature of an object to be tested.
Alternatively, it is an object of this invention to effectively perform pattern inspection by selecting a pattern comparison technique in a way pursuant to the pattern feature of an object being tested.
An alternative object of the invention is to shorten a pattern inspection time period by selecting a pattern comparison scheme in accordance with the pattern feature of an object under test.
An alternative object of the invention lies in providing pattern inspection apparatus and methodology capable of offering enhanced performances by selecting a pattern comparison scheme in accordance with the pattern feature of a test object or, alternatively, to obtain a reticle adaptable for use therein.
In accordance with a first aspect of the invention, a pattern inspection apparatus is provided, which includes an optical image acquisition unit that operates to obtain an optical image of an object being tested, a plurality of types of feature comparison units each of which compares, based on feature data indicative of pattern features of the optical image of the test object, identical patterns at different positions on the test object, and a selector unit which selects, during comparison of the identical patterns of the optical image, a kind of feature comparison unit from the feature data of a pattern under inspection.
In accordance with a second aspect of the invention, a pattern inspection apparatus includes an optical image acquisition unit which operates to obtain an optical image of an object being tested, a reference image creation unit which makes a reference image from pattern design data of the test object, a plurality of types of feature comparison units operable to compare, based on feature data indicative of pattern features of the test object, the optical image to the reference image, and a selector unit which selects, when comparing between the optical image and the reference image, a kind of feature comparison unit from the feature data of a pattern to be inspected.
In accordance with a third aspect of the invention, a pattern inspection method is provided, which includes an optical image acquisition step of obtaining an optical image of an object being tested, a plurality of kinds of feature comparison steps of comparing, based on feature data indicative of pattern features of the test object, identical patterns at different positions on the test object, and a selection step of selecting, when comparing an optical image and a reference image, a feature comparison step from the feature data of a pattern under inspection.
In accordance with a fourth aspect of the invention, a pattern inspection method includes an optical image acquisition step of acquiring an optical image of an object being tested, a reference image creation step of making a reference image from design data of a pattern of the test object, a plurality of kinds of feature comparison steps of comparing, based on feature data indicative of pattern features of the test object, the optical image to the reference image, and a selection step of selecting, when comparing the optical image to the reference image, a feature comparison step from the feature data of a pattern under inspection.
In accordance with a fifth aspect of the invention, a reticle is provided, which is subjected to pattern inspection by common optical image comparison with respect to identical patterns at different position on the reticle. Furthermore, the reticle is pattern-inspected by a plurality of kinds of optical image feature comparisons as applied to the reticle based on the feature data indicative of reticle pattern features concerning identical patterns at different positions on the reticle.
In accordance with a sixth aspect of the invention, a reticle is provided, which is subjected to pattern inspection by common comparison of an optical image of the reticle to a reference image. The reticle is also applied further pattern inspection by means of a plurality of kinds of feature comparisons of optical and reference images based on feature data indicative of reticle pattern features.
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.
An explanation will now be given of the pattern inspection of an object being tested, such as a reticle, in accordance with a currently preferred embodiment of this invention.
(Pattern Inspection Apparatus)
A pattern inspection apparatus is the one that inspects an object under test, such as a reticle, to determine whether a pattern formed thereon has a prespecified shape in an expected manner. The pattern inspection apparatus includes an optical image acquisition unit, which functions to scan a pattern that is drawn on the test object to thereby obtain the data of an optical image, and then compare data of identical patterns at different locations of this test object to thereby inspect the test object to verify whether its pattern is formed into a prespecified shape (die-to-die inspection). The test object has a pattern which is to be transferred or “imaged” onto substrates, such as for example semiconductor wafers or liquid crystal (LC) base plates.
Alternatively, the pattern inspection apparatus is operable to scan a pattern drawn on a test object to obtain the data of an optical image at the optical image acquisition unit and also processes, at a reference image creation unit of a data processing unit, design data which becomes the “source” of a pattern image for depiction onto the test object, thereby obtaining reference image data. The pattern inspection apparatus operates to compare the optical image data to the reference image data at a comparator unit and performs inspection to determine whether the test object's pattern is formed to have an expected shape (die-to-database inspection). The design data is a “base” used for pattern depiction on the test object. It should be noted here that although the explanation below assumes that the test object is a reticle, this test object may be any ones with a circuit pattern formed thereon, including a photomask, wafer and equivalents thereto.
The comparator unit includes a plurality of feature comparator modules with different functionalities. Each feature comparator is for performing pattern comparison based on the pattern feature of either the reticle's optical image or the reference image. These feature comparators are provided in units of patterns. Selection of a feature comparator of the test object pattern is carried out while referring to feature data, which is in use during pattern comparison at the feature comparator.
The feature data used here is the one that designates a specific pattern of reticle image and indicates a feature portion(s) of the reticle image. The feature data is created, for example, at the stage of designing the reticle image in such a manner as to correspond to reticle pattern positions, and thus is pattern identification data for pattern designation. The feature data may be designed to indicate characteristic portions of the reticle image. The feature data can be represented by an image in a way corresponding to the reticle image, for example. The feature data indicates, for example, a pattern linewidth, an amount of pattern-transmitted light, a pattern edge roughness, or a relative position(s) near or around the pattern. Note that the pattern as used in the illustrative embodiment may have any shape as far as it is mutually comparable—for example, an independent pattern, a combination of more than two independent patterns, a pattern of a portion (one part) of independent pattern, or a pattern of a portion (part) of those patterns coupled together. The comparator is equipped with a common comparator unit when the need arises. The common comparator is operable to perform image comparison without having to refer to the feature data. The common comparator has a comparison means for common use to all patterns between images.
As shown in
The pattern inspection apparatus compares images at the common comparator 3. The common comparator 3 compares the optical image 100 to the reference image 200 in accordance with an adequate algorithm to thereby determine or “judge” whether pattern defects are present or absent. One example is that the pattern inspection apparatus compares the optical image 100 to reference image 200 and then identifies whether a difference therebetween exceeds a predefined threshold to thereby judge the presence or absence of defects. When more than one defect is found, let the data of such defect be stored in a database 140. If no defects are found then perform image comparison in accordance with the feature of the pattern being tested. To do this, the pattern inspection apparatus has a plurality of feature comparator units 1, 2, . . . , i, . . . , n in a way pursuant to the pattern feature. To indicate the feature of reticle image, the pattern inspection apparatus has a collection of feature data 202 corresponding to the reticle's positions. Upon comparison between optical images or comparison of an optical image to reference image, refer to the feature data 202 for allowing a comparison means selector unit 4 to select one from among the feature comparators 1-n. Whereby, it is possible to perform the intended image comparison in accordance with the feature of an image pattern under test. The results of such image comparison, which include the contents of reticle pattern errors and positions of such errors or else, are stored in the database 140. Those patterns to be designated by the feature data typically include a pattern with its comparison accuracy increasing in compliance with the pattern feature, and a pattern that requires accurate comparison. A means for comparing a pattern that is designated by the feature data is arranged, for example, to measure for comparison the linewidth of a pattern, measure for comparison the amount of light that passed through the pattern, measure for comparison the pattern edge roughness, or measure for comparison a relative position near or around the pattern. Whether the image of interest is good or bad is determinable by using the comparison result to determine whether the value of its difference is above the threshold. Providing this type of feature comparator unit makes it possible to achieve accurate pattern inspection in conformity with the pattern feature. It is also possible to shorten a pattern inspection time as a whole, since the testing time is assignable to necessary patterns only while precluding the test time for immaterial patterns.
Although in
As shown in
(Optical Image Acquisition Unit)
The optical image acquisition unit 10 is operable to acquire the optical image of a reticle 101. The reticle 101 is for use as an object to be inspected and is mounted on the XYθ table 102. The XYθ table 102 is driven by the X-, Y- and θ-motors 151, 152, 150 to move in horizontal and rotation directions. This table 102 is motion-controlled in response to a command signal from the table controller 114. Light emitted from the light source 103 is guided to fall onto the pattern as formed on the reticle 101. Light that passed through the reticle 101 is then guided to travel through the magnification optics 104 to hit the photodiode (PD) array 105 so that a focused optical image is formed thereon. An image that was captured by the PD array 105 is processed by the sensor circuit 106 and is then photoelectrically converted into data of the sensed optical image for comparison with a reference image.
A procedure for optical image acquisition will be explained with reference to
The pattern image thus focused on the PD array 105 is photoelectrically converted thereby into an electrical image signal, which is then analog-to-digital (A/D) converted by the sensor circuit 106 to a corresponding digital signal. The light source 103, magnifying optics 104, PD array 105 and sensor circuit 106 make up an inspection optical system of high magnifying power.
The XYθ table 102 is driven by the table controller 114 under control of the CPU 110. A moved position of the XYθ table 102 is measured by the laser-assisted length measurement system 122 and is then sent forth toward the position measurement unit 107. The reticle 101 on the table 102 is transported from the auto-loader 130 under control of the auto-loader controller 113. Measured pattern data of each test strip 5 as output from the sensor circuit 106 is passed to the comparator unit 108 along with the data indicative of a present position of the reticle 101 on XYθ table 102 as output from the position measurement circuit 107. The data of an optical image and the reference image of an object to be compared are cut or “diced” into areas each having an appropriate pixel size—for example, 512×512 pixel regions. Although the optical image stated above is obtained using the transmitted light, similar results are attainable by use of reflected light, scattered light, polarized scatter light, polarized transmit light or equivalents thereof.
(Reference Image Creation Unit)
The reference image creation unit 20 is the one that creates a reference image. The reference image creator 20 uses the design data of a reticle under inspection to make a reference image that resembles the optical image of interest. The reference image creator 20 prepares such reference image through execution of various kinds of conversion operations with respect to the design data. The reference image creator 20 is configurable, for example in
(Pattern Inspection Method)
A pattern inspection method is to inspect the pattern of a reticle for defects. As shown in
In case no defects are found, a feature comparison technique is used to perform more accurate image inspection. The feature comparison technique is such that a plurality of comparison schemes are provided in accordance with pattern features. Let these comparison schemes be a feature comparison scheme 1, a feature comparison scheme 2, . . . , a feature comparison scheme n. Each feature comparison scheme is associated with feature data indicative of a specific kind of preset reticle pattern feature. When performing image comparison, in an image being tested, refer to the feature data (at step S5); then, select one from among the feature comparison schemes (at select step S6); next, perform image comparison using the selected feature comparison scheme (at feature comparison step S7, S8, S9). When defects are found by any one of the feature comparison schemes, this reticle is determined to be defective (at step S10). Alternatively, in case an affirmative inspection result is obtained by any one of the feature comparison schemes, the reticle is handled as a defect-free product (at step S10). Using this comparison technique makes it possible to achieve adequate and highly accurate pattern inspection in accordance with the pattern feature of interest. In addition, it becomes possible to adjust the length of inspection time period in such a way that a sufficient testing time is reserved for necessary patterns only while saving time for inspection of immaterial patterns that are less in importance. This makes it possible to increase the efficiency of pattern inspection, thereby enabling cut-down of the pattern inspection time as a whole.
Although in
(Reticle Inspected)
A reticle is pattern-formed by lithography equipment using design data. The reticle prepared is then subjected to optical image inspection by the pattern inspection apparatus stated supra. In this event, pattern inspection is carried out through comparison of an optical image and a reference image. This comparison method is performed by feature comparison taking account of feature data, whereby comparison with the weighting of such feature data being considered is carried out. As a result, it is possible to obtain the intended reticle having a more accurate pattern image. Optionally, during the comparison of optical and reference images, the feature comparison and the common comparison may be combined together.
A pattern featuring a reticle image is shown in
In the case of comparison between reticle optical images or alternatively comparison between an optical image and a reference image, when the above-noted feature data is given to a reticle under inspection, the reticle's image is inspected in accordance with the system procedure shown in the flow diagram of
Pattern linewidth comparison means and method of the feature data 2 are implemented as shown in
Comparison of relative positions of neighboring pattern segments of the feature data 3 is as follows. Obtain a profile of tone value of
Regarding comparison of the edge roughness of the feature data 4, in a cross-section indicated by broken line in
See
Additional advantages and modifications will readily occur to those skilled in the art to which the invention pertains. 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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2005-259162 | Sep 2005 | JP | national |