Ryoichi Hirano

A mask‐to‐wafer alignment and gap setting method for x‐ray lithography using gratings

A new optical‐heterodyne interferometry alignment and gap setting method for x‐ray lithography is developed, where the phases of beat signals are used for detection. The fact that the lateral displacement and the gap between mask and wafer can be detected independently is shown, based on the results of analysis and experiments. Two pairs of gratings are arranged as detection marks. One pair forms a window on the mask and a checkerboard grating on the wafer, while another pair forms two linear gratings at right angles to each other. Two He‐Ne laser beams with slightly different frequencies illuminate the gratings from the ±1st‐order diffraction light directions. The lateral displacement is detected by measuring the beat signal phase difference between the two (0,1)th‐order diffraction lights from two pairs of gratings. To detect the gap, the signal phase difference between the (0,1)th‐ and (1,1)th‐order diffraction lights from the pair of linear gratings is used. Better than 0.02 μm (3σ) alignment repeatability and 0.1 μm gap setting accuracy have been achieved.

Development of extreme ultraviolet mask pattern inspection technology using projection electron beam optics

Abstract. Extreme ultraviolet (EUV) lithography with a 13.5 nm exposure wavelength is a leading candidate for the next-generation lithography because of its excellent resolution for 16 nm half pitch (hp) node devices and beyond. High sensitivity EUV mask pattern defect detection is one of the major issues to realize device fabrication with EUV lithography. First, to estimate targeted pattern defect detection size, a simulation for defect printability was carried out. In order to achieve the required inspection sensitivity applicable for 1X nm node, a projection electron microscopy (PEM) system was employed, which enabled us to do inspection in higher resolution and with higher speed in comparison to those of the conventional deep ultraviolet and electron beam inspection systems. By incorporating high electron energy and low optical aberration into the PEM, we designed a system for 16 nm hp node defect inspection. To guarantee the quality of the 16 nm node EUV mask, corresponding sized programmed defect masks were designed, and a PEM system defect detection was evaluated by using the current system for 2X nm generation.

Patterned mask inspection technology with projection electron microscope technique on extreme ultraviolet masks

Abstract. High-sensitivity extreme ultraviolet (EUV) mask pattern defect detection is one of the major issues remaining to be addressed in device fabrication using extreme ultraviolet lithography. In order to achieve inspection sensitivity and suitability for the 1× nm node, a projection electron microscope (PEM) system is employed that enables high-speed/high-resolution inspection, which is not possible using conventional deep ultraviolet or electron beam inspection systems. By employing higher electron energy in the electron optics (EO) exposure system and by improving the PEM design, we have minimized the aberration that occurs when working with EO systems and we have improved the transmittance of the system. Experimental results showing the improved transmittance were obtained by making electron throughput measurements. To guarantee the tool’s aptness for 16-nm node EUV mask inspection, corresponding sized programmed defects on masks were designed, and the defect detection sensitivity of the EO system was evaluated. Improvements in image resolution and electron throughput have enabled us to detect 16-nm sized defects. The PEM system was integrated into a pattern inspection system for defect detection sensitivity evaluation.

Advanced electron-beam writing system EX-11 for next-generation mask fabrication

Toshiba and Toshiba Machine have developed an advanced electron beam writing system EX-11 for next-generation mask fabrication. EX-11 is a 50 kV variable-shaped beam lithography system for manufacturing 4x masks for 0.15 - 0.18 micrometer technology generation. Many breakthroughs were studied and applied to EX-11 to meet future mask-fabrication requirements, such as critical dimension and positioning accuracy. We have verified the accuracy required for 0.15 - 0.18 micrometer generation.

Impact of electron scattering in extreme ultraviolet reflective multilayer on electron image

Impact of electron scattering in extreme ultraviolet reflective multilayer (ML) on electron image was investigated. The secondary electron emission coefficient of Ru capped ML was lower than that of Ru bulk layer when the incident electron energy was more than 0.5 keV. In ML, the backscattered electrons (BSEs) diffused laterally along the Si layer and escaped from the Ru surface, while generating secondary electrons. As a result, spatial intensity distribution of the emitted electrons within the ML sample was broader than that of the Ru bulk sample. The deep and broad undershot dip appeared in the profile of scanning electron microscope image for knife-edge pattern on ML sample. This was because the BSEs near the edge diffused laterally and were blocked from escaping from the sample surface by the absorber layer. In the case of hp 50 nm line-and-space (L/S) pattern, dips appeared only for Ru bulk samples, because the dense L/S pattern profile is essentially a summation of two opposing knife-edges. Simulat...

Extreme ultraviolet mask defect inspection with a half pitch 16-nm node using simulated projection electron microscope images

Abstract. According to an International Technology Roadmap for Semiconductors (ITRS-2012) update, the sensitivity requirement for an extreme ultraviolet (EUV) mask pattern inspection system is to be less than 18 nm for half pitch (hp) 16-nm node devices. The inspection sensitivity of extrusion and intrusion defects on hp 64-nm line-and-space patterned EUV mask were investigated using simulated projection electron microscope (PEM) images. The obtained defect images showed that the optimization of current density and image processing techniques were essential for the detection of defects. Extrusion and intrusion defects 16 nm in size were detected on images formed by 3000 electrons per pixel. The landing energy also greatly influenced the defect detection efficiency. These influences were different for extrusion and intrusion defects. These results were in good agreement with experimentally obtained yield curves of the mask materials and the elevation angles of the defects. These results suggest that the PEM technique has a potential to detect 16-nm size defects on an hp 64-nm patterned EUV mask.

Impact of B4C capping layer for extreme ultraviolet mask on the sensitivity of patterned mask inspection using a projection electron microscope

Abstract. The inspection sensitivity of a patterned extreme ultraviolet mask with B4C-capped multilayer (ML) was investigated using a simulated projection electron microscope (PEM) image. Extrusion and intrusion defects with 16-nm size were detected with their intensity of >10 times the standard deviation of the background level on a half-pitch 64-nm line-and-space pattern. The defect detection sensitivity in this case was higher than that of a Ru-capped ML sample and has a potential to meet the requirement for beyond 16-nm node generation from the standpoint of patterned mask inspection using the PEM technique. These results indicate that the B4C capping layer, besides its good durability, has an advantage for high sensitivity of patterned mask inspection. The optimal condition of the incident beam energy was found to be 500 and 1,000 eV for the samples of B4C-capped ML and B4C-buffered Ru-capped ML, respectively. The sensitivity of defect detection was strongly affected by the difference of secondary electron emission coefficients (SEECs) between the absorber layer and capping layer. However, the small incident beam energy was found to be preferable when the SEEC difference was relatively high.

A novel defect detection optical system using 199-nm light source for EUVL mask

Lithography potential expands for 45nm node to 32nm device production by the development of immersion technology and the introduction of phase shift mask. We have already developed the mask inspection system using 199nm wavelength with simultaneous transmitted illumination and reflected illumination optics, and is an effectual candidate for hp 32nm node mask inspection. Also, it has high defect sensitivity because of its high optical resolution, so as to be utilized for leading edge mask to next generation lithography. EUV lithography with 13.5nm exposure wavelength is dominant candidate for the next generation lithography because of its excellent resolution for 2x half pitch (hp) node device. But, applying 199nm optics to complicated lithography exposure tool option for hp2x nm node and beyond, further development such as image contrast enhancement will be needed. EUVL-mask has different configuration from transmitted type optical-mask. It is utilized for reflected illumination type exposure tool. Its membrane structure has reverse contrast compared with optical-mask. This nature leads image profile difference from optical-mask. A feasibility study was conducted for EUV mask pattern defect inspection using DUV illumination optics with two TDI (Time Delay Integration) sensors. To optimize the inspection system configuration, newly developed Nonlinear Image Contrast Enhancement method (NICE) is presented. This function capability greatly enhances inspectability of EUVL mask.

New mask blank handling system for the advanced electron-beam writer

Meeting the latest requirements of aggressive users for advanced masks for optical lithography will be difficult. In addition, improving the productivity and throughput of advanced masks with high-density pattern data is necessary. To overcome these hurdles, Toshiba and Toshiba Machine have developed a new advanced mask writer, the EX-11, shown in Figure 1. The EX-11 takes measures against airborne contamination before drawing is started. It also employs a standard mechanical interface (SMIF) based on the concept of local cleaning technology. This paper describes the design concept of the new mask blank handling system for the EX-11, and the efficiency of these measures was confirmed by the experimental results.

Observation of Residual-Type Thin Absorber Defect on Extreme Ultraviolet Lithography Mask Using an Extreme Ultraviolet Microscope

A local etching technique using electron beams has been proposed to repair defects on an absorber pattern. In this paper, the effect of pattern contrast over a thin absorber film left on a multilayer was examined. Various residual absorber films on the multilayer were fabricated and examined using an extreme ultraviolet (EUV) microscope employed as an at-wavelength mask pattern inspection tool. As a result, the contrast decreased by 30% in the remaining thickness of 2.9 nm for half-pitch 225 nm features. The EUV microscope proved to be an effective tool for examining the post repair effects.