Patent ID: 8019458
Filing Date: 2011-09-13
Classification: G05B,Y10S

Abstract:
1. A method for establishing a Multi-Layer/Multi-Input/Multi-Output (MLMIMO) model for creating a plurality of metal-gate structures on a patterned wafer, the method comprising: selecting a first Multi-Layer-Multi-Step (MLMS) processing sequence and a first Multi-Layer-Multi-Input-Multi-Output (MLMIMO) model, the first MLMS processing sequence being configured to create a patterned hard-mask layer on a second set of wafers using a patterned soft-mask layer on a first set of wafers, the patterned hard-mask layer including one or more hard-mask structures, wherein the first MLMIMO model is configured to simulate the first MLMS processing sequence and includes a plurality of first Controlled Variables (CVs), a plurality of first Manipulated Variables (MVs), and a plurality of first Disturbance Variables (DVs); selecting a second Multi-Layer-Multi-Step (MLMS) processing sequence and a second Multi-Layer-Multi-Input-Multi-Output (MLMIMO) model a second Multi-Layer-Multi-Step (MLMS) processing sequence, the second MLMS processing sequence being configured to create one or more patterned metal-gate layers on a third set of wafers using the patterned hard-mask layer on the second set of wafers, the patterned metal-gate layers having one or more metal-gate structures, wherein the second MLMIMO model is configured to simulate the second MLMS processing sequence and includes a second number (L determining a first number (N determining a first number (L establishing a first number (M analyzing the first MLMIMO model, wherein one or more first statistical models are selected, one or more first ranges are provided for the first (CV determining one or more first stability conditions for the first MLMIMO model; and optimizing the first MLMIMO model using performance parameters associated with a first set of processing tools configured to perform the first MLMS processing sequence.