This application claims priority to Japanese Patent Application No. 2006-010760, filed Jan. 19, 2006, the disclosure of which is incorporated herein by reference.
1. Field of the Invention
The present invention relates generally to workpiece pattern inspection technologies and, more particularly, to a method and apparatus for inspecting for defects the pattern of a photomask, called “reticle,” which is used in the manufacture of semiconductor devices and liquid crystal display (LCD) panels. This invention also relates to a workpiece tested by the pattern inspection apparatus and method.
2. Description of Related Art
Prior known pattern inspection methodology includes methods for applying simulation processing to a photomask of highly integrated circuit devices to thereby inspect the mask for defects. An example of the inspection methods is disclosed in Published Translated International Application No. 2005-500671. Unfortunately this method as taught thereby suffers from limited inspection capabilities. This can be said because the method is merely designed to inspect a “finalized” pattern after completion of the simulation applied thereto.
With recent advances in miniaturization of semiconductor devices, pattern transfer inspection decreases in margin. This raises a need to perform defect check with precision high enough to permit probing of an exact level of the final transfer margin while fitting inspection conditions to de facto conditions.
Due to this, simply using this technique makes it inevitable to execute margin ascertainment under every possible set of transfer conditions. This would require troublesome and time-consuming data processing and thus lacks practical applicability.
It is therefore an object of this invention to provide a pattern inspection method and apparatus capable of performing highly accurate inspection while offering an ability to find emphatic portions of defects temporarily appearing in the process of transfer/development simulation of the image of a workpiece being tested. It is another object of the invention to obtain a workpiece that is tested by the pattern inspection method and apparatus.
Currently preferred embodiments of the invention are arranged to perform simulation processing under ordinary or “standard” process conditions of a workpiece to be inspected, such as a reticle. Pattern inspection is carried out in mid course of the simulation, thereby finding defect candidates on a real time basis. This avoids the need to establish every possible set of process conditions. A high precision level of or “detailed” simulation processing is applied only to such defect candidates thus found, so it becomes possible to achieve inspection with enhanced accuracy. This makes it possible to efficiently check the workpiece for defects. More particularly, but not exclusively, the invention may be implemented in several forms which follow.
In accordance with one aspect of the invention, a pattern inspection apparatus includes a captured image storage unit which stores therein a pattern of an image acquired from an image of a workpiece to be tested, a simulator unit operative to apply transfer/development simulation to the pattern of the acquired image, a simulation image storage unit which stores a pattern of an image obtained in mid course of simulation during the transfer/development simulation of the pattern of the acquired image, and a comparison processor unit that operates to regard as a pattern to be tested the pattern of a during-simulation image of the acquired image while using a pattern to be compared as a fiducial pattern and then compare the to-be-tested image to the fiducial pattern.
In accordance with another aspect of the invention, a pattern inspection method includes the steps of applying transfer/development simulation to the pattern of an image which is acquired from the image of a workpiece to be tested, storing the pattern of an image being presently simulated during the transfer/development simulation of the pattern of the acquired image, and comparing, while letting the presently simulated image be a pattern to be tested and letting a to-be-compared pattern be a fiducial pattern, the to-be-tested pattern to the fiducial pattern.
In accordance with a further aspect of the invention, a workpiece is provided which was obtained by a process including applying transfer/development simulation to the pattern of an image captured from the image of a workpiece to be tested, storing the pattern of an image being presently simulated in mid course of the transfer/development simulation of the pattern of the acquired image, and comparing a pattern of the presently simulated image to a pattern to be compared.
A workpiece pattern image inspection technique incorporating the principles of this invention will be set forth below. The workpiece to be tested here is a reticle as an example.
Principally the pattern inspection embodying the invention is a process which includes the steps of acquiring the optical image of a workpiece being tested, applying transfer/development simulation processing to the pattern of such optical image under specified process conditions, and inspecting more than one pattern which is obtained in mid course of the transfer/development simulation to thereby examine whether abnormal patterns such as defective pattern portions are present or not. During transfer/development simulation of the image, it can sometimes happen that its defective portions are temporarily emphasized. By finding such emphasized defects, it is possible to perform pattern inspection with enhanced accuracy. For example, suppose that an abnormal pattern is found by inspection of a pattern in mid course of the transfer/development simulation. In this case, store it as a “candidate” of defective part, and then continue and complete the transfer/development simulation with respect to defect candidates only. As for certain locations at which no abnormal patterns are found, interrupt the transfer/development simulation. Then, inspect the finally processed pattern to determine whether the abnormal pattern is a “true” defective portion or not. Alternatively, inspect a pattern being presently subjected to simulation. If an abnormal pattern is found then store it as the candidate of a defective portion. Next, apply the transfer/development simulation only to such abnormal pattern under more precise process conditions than the specified process conditions. For the remaining portions whereat no abnormal patterns are found, halt the transfer/development simulation or, alternatively, apply thereto the transfer/development simulation under the specified process conditions. With these processes, it is possible to lessen the arithmetic computation amount of the transfer/development simulation, thereby making it possible to efficiency inspect the workpiece pattern for defects with increased accuracy. In addition, by executing the transfer/development simulation to its end, it becomes possible to reduce or “curtail” defect candidates. This makes it possible to achieve the screening of the defect candidates.
The optical image may be a pattern image which is captured by an optical image acquisition unit. Note that although the description assumes the handling of optical images, the invention should not be exclusively limited thereto and may alternatively be other types of pattern images acquired by non-contact or contact means. Examples of the images include, but not limited to, a laser beam-scanned image, an observational image obtainable by scanning electron microscope (SEM) equipment, an image obtained by scanning tunneling microscope (STM) tools, an image gained by non-contact interatomic force (NC-AF) means, and an X-ray sensed image. Additionally the above-stated transfer/development simulation processing may be known simulation scheme-based image manipulation, such as transfer simulation and/or development simulation or else. The transfer/development simulation is performed with settings of a variety of process conditions, such as exposure and etching conditions. The process conditions include various ones such as short-time rough processing conditions, long-time precise processing conditions or else. Although the description assumes that the workpiece being tested is a reticle, the workpiece may alternatively be other objects as far as these have a surface on which a pattern is formed for use in the manufacture of semiconductor devices and LCD panels, such as for example photomasks, wafers, etc. The term “pattern” as used herein should be interpreted to mean an entire pattern or a partial pattern.
Referring to
An exemplary system configuration of pattern inspection apparatus 200 is shown in
The optical image acquisition unit 210 functions to capture the optical image of a reticle 220. This reticle 220 is mounted on the XYθ table 218. XYθ table 218 is a three-axis (X-Y-θ) manipulator which is movable in X and Y directions with or without rotation by angle θ under control of the table controller 248, which is operatively responsive to receipt of a command(s) from CPU 242. Table 218 is driven by the X motor 224 in the X direction, by Y motor 226 in Y direction, and by θ motor 222 in θ direction. These motors may be known servo motors, stepper motors or other electrical motors. The coordinates of a present position of XYθ table 218 is measured by the laser length meter 214, an output signal of which is sent to the position measurement unit 258. Output position coordinate data of this unit 258 is fed back to the table controller 248.
The reticle 220 is automatically transferred to and mounted on the XYθ table 218 by auto-loader 212 and, after inspection, automatically unloaded thereby. The light source 216 and light irradiation unit 217 are located over XYθ table 218. The light source 216 emits light, which is guided by a condenser lens assembly of the light irradiator 217 to fall onto the reticle 220 as a focused light beam. At a location underlying the reticle 220, a signal detection unit is disposed, which includes the magnifying optics 228 and PD array 230. The light that passed through reticle 220 is focused by magnifier optics 228 onto a photosensitive surface of PD array 230. The optics 228 is subjected to automatic focus adjustment by a focus adjuster device (not shown), which includes piezoelectric elements or the like. This focus adjuster is operation-controlled by an auto-focus control circuit (not shown), which is connected to the CPU 242. The focus adjustment may alternatively be monitored by a separately provided observation scope. The PD array 230 for use as a photoelectric converter may be a linear array of multiple photosensors or an area sensor having a matrix of rows and columns of PDs. While letting XYθ table 218 move continuously in X direction, PD array 230 detects a measurement signal corresponding to a sensed image of reticle 220.
This measurement signal is converted by the sensor circuit 232 into digital data, which is then passed as the data of the optical image to the buffer memory 246, main storage 266 and external storage 260. The optical image data may be eight (8) bits of sign-less data indicative of the brightness of each picture element or “pixel.” The pattern inspection apparatus 200 of this type is usually operates to read the pattern data out of the PD array 230 in a way synchronous with a clock frequency of about 10 to 30 megahertz (MHz), get them lined up to provide an adequate form of data, and handle as raster-scanned two-dimensional (2D) image data.
See
The measured pattern data of the reticle strips 30 as output from the sensor circuit 232 are sent to the comparison processor 254 along with the output data of position measurement unit 258 indicative of a present position of reticle 220 on XYθ table 218. An optical image to be compared is cut into partial areas of an appropriate size; for example, regions each having a matrix of 512 by 512 pixels. Although the optical image is captured here by using the light that passed through reticle 220, similar results are obtainable by use of reflection light, scattered light, polarized scatter light, polarized transmission light or else. To detect these image light rays, the image acquisitor 210 has a built-in image capturing mechanism for pick up of the images of these rays.
A reference image is an image that was prepared to have much similarity to the optical image by execution of various conversion processes from the design data of the reticle 220. The reference image is preparable, for example, by the reference image creator 252 in a way which follows. Access is given to either the external storage 260 or the main storage 266 to read therefrom the design data of the pattern image of reticle 220 under control of CPU 242. Then, convert the read data into image data. Next, perform image resembling processing—e.g., rounding corner edges of graphic forms, gradating or “fogging,” or other similar suitable image manipulation—to thereby create the reference image. The reference image thus created is stored in the external storage 260 or internal main storage 266.
The comparison processor 254 compares between images to determine whether defects are present or absent. There are several approaches to doing image comparison, one of which is die-to-die (DD) comparison, and another of which is die-to-database (DB) comparison. The DD comparison is to compare a die on a reticle to another on the reticle. The DB comparison is for comparing a die on reticle to a reference image. The DD and DB comparison schemes include a process of detecting a change in transmissivity, foreign matter attachment, ultrafine edge positions or ultrasmall intensity variation. The comparison processor 254 enables achievement of more accurate deterioration testing by performing comparison of micro-shapes such as contact holes, setup of a margin pursuant to the materiality of graphic figure, and setting of area sensitivity depending on graphics features.
See
Referring to
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Another exemplary procedure is shown in
While this invention has been described with reference to specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. The invention is, therefore, to be limited only as indicated by the scope of the appended claims.
Number | Date | Country | Kind |
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2006-010760 | Jan 2006 | JP | national |