Feed-forward lithographic overlay offset method and system

[0002] 1. Field of the Invention

[0003] This invention generally relates to semiconductor lithography, and more specifically to addressing overlay errors that can occur in semiconductor lithography.

[0004] 2. Prior Art

[0005] One of the most important requirements for semiconductor lithography is overlay, or image placement of one lithographic level relative to another. Overlay errors of one level relative to the prior level are often numerically broken down into systematic and non-systematic components; systematic components are typically: X and Y translation [zeroth order error]; and Lithographic field X and Y magnification, rotation, and skew [first order error across the wafer]

[0006] These zeroth and first-order components are chosen specifically because the errors are relatively easily correctable, and while there are repeatable higher-order effects, they are typically not easily fixable and are lumped in as “residual” errors. The correctable components are often referred to as overlay systematics, and are used to generate overlay offsets (settings) which are transferred to the aligner to achieve proper overlay.

[0007] To achieve good overlay, there are numerous approaches. For “easy” (loose overlay specification relative to aligner and process capability) levels, a fixed set of overlay offsets can be used with reasonable success. As specifications tighten, it is necessary to periodically update overlay offsets. One method of this update is to couple a database with a software data filtering means and averaging algorithm to automatically adjust these offsets. Because of either process/aligner variability or aligner shifts, an average of past offsets, no matter how well sorted, is not necessarily the optimum predictor of what a current lot needs for best overlay. In summary, the current state of the art uses feedback methods, based on population means, as a predictor for aligner settings.

[0008] The problem of optimized overlay is central to all semiconductor lithography fabrication. Existing methods for addressing this problem typically use population averaging to remove noise or slowly react to change.

[0009] An object of this invention is to improve overlay offset methods and systems for semiconductor lithography.

[0010] Another object of the present invention is to provide feed-forward methods, in semiconductor lithography procedures, based on correlation of current and prior aligned levels, to predict optimum overlay offsets for a given lot.

[0011] These and other objectives are attained with a method and system embodying the present invention for predicting systematic overlay affects in semiconcductor lithography. This method is a feed-forward method, based on correlation of current and prior aligned levels, to predict optimum overlay offsets for a given lot. Instead of using population averaging, which ignores process variability, it acknowledges the variability and uses prior measurements to advantage. The principle, backed by production data, is that “systematic” overlay errors are just that: Image placement errors which persist through processing and will be predictable through time and processing.

[0012] For example: If a first lithographic level is exposed and etched with a two microradian (μrad) rotation error, this is measurable after lithography. It is reasonable to expect (and has been experimentally proven) that this rotation error persists and is measurable at the second lithograpbic level. Although ideally this systematic distortion should measure two urad at the second level, measurement errors at either level, coupled with uncorrectable lithographic distortion, make a linear correlation with non-zero intercept likely. In addition, because of overlay calculation connections, the ideal slope for the correlation would be either +1 or −1.

[0013] Further benefits and advantages of the invention will become apparent from a consideration of the following detailed description, given with reference to the accompanying drawings, which specify and show preferred embodiments of the invention.

[0014] FIG. 1 outlines a preferred method embodying this invention.

[0015] FIG. 2 shows a linear correlation among lithographic overlays of a first product lot.

[0016] FIG. 3 is a table giving data obtained from the first product lot.

[0017] FIG. 4 is a table providing data obtained from a second product lot.

[0018] FIGS. 5 and 6 show correlations between two memory aligned lithography levels.

[0019] The present invention, generally, provides for methods and systems of predicting systematic overlay effects in semiconductor lithography. With reference to FIG. 1, this, in a preferred embodiment, can be done by creating a database of overlay systematics for each lot processed at a first lithographic level and second lithographic level by measuring overlay, and recording these systematic errors and the lot identification. These systematic errors can be derived either for an unaligned level using known field-butting techniques; or for aligned levels, using conventional “box-in-box” structure measurements as already performed in the fabricator. The preferred method of this invention further comprises the steps of creating a correlation between each overlay offset at the second lithographic level relative to the first lithographic level; for a new lot, measuring the overlay systematics at the first lithographic level; and using the correlation between the overlay offsets, and the data from the first lithographic level, to predict the optimum overlay offsets at the second lithographic level.

[0020] This preferred embodiment may be enhanced in a number of ways. For instance, the correlation can be fine tuned by sorting according to various parameters, such as reticle, tool, lithographic level, and others. Also, the most straightforward and logical correlation would involve a linear relation, with simple linear regression techniques available. Optionally, the data can be statistically sorted to exclude outlying “flyers” (e.g. chi-squared test). Also, limits can be placed on the correlation coefficient, requiring a minimum r-squared value to utilize the correlation. As another option, limits can be placed on the intercept, requiring that it be within a certain offset of 0. If any limits are exceeded, then the algorithm to calculate overlay offsets would revert to the current population averaging techniques.

[0021] Optionally, if valid correlations exist on multiple align tools, the average of these correlations can be used to predict behavior on a new tool at the second lithographic level. As another option, if valid correlations exist for lithographic level 2 to level 1 on two tools; and a correlation exists for lithographic level 4 to level 3 on one of the tools, the difference between the two correlations on the first tool can be used to predict the correlation of level 4 to level 3 on the second tool.

[0022] The present invention does not ignore the population variability by averaging it; it acknowledges that variability is intrinsic to the process and takes advantage of it. The invention seeks to identify repeatable, predictable, sustainable variation in the process and uses it to feed predictable change forward to the next lithographic level. Population averaging treats all variability as unrepeatable noise, thus in essence discarding valuable, usable data.

[0023] This invention has been tested with two rounds of product, referred to herein as CMOS 1 and CMOS 2. Five CMOS 1 lots were overridden with projected (linear) correlations, shown in FIG. 2, and exposed over three days. As the data in FIG. 3 shows, about 3×improvement in field rotation errors was realized. This would result in approximately a 15-20 nm improvement in maximum error vector versus the current state of the art.

[0024] In the second round of product, six CMOS 2 lots were overridden with projected linear correlations, with projected linear correlations for field rotation and skew only, and exposed for over seven days. As the data in FIG. 4 shows, about a 4×improvement in field skew relative to current methods was achieved.

[0025] The above methods addressed field systematics, as the initial level was an unaligned RX level using field butting measurements to infer field systematics. Similar correlations have been successfully established, but not yet tested, between two memory aligned levels. Two examples are shown in FIGS. 5 and 6.

[0026] While it is apparent that the invention herein disclosed is well calculated to fulfill the objects stated above, it will be appreciated that numerous modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention.