Abstract:
A method of cleaning calibration and other substrates that improves the correlation of measurements from calibration and product substrates and increases the useful life of the calibration substrates is herein disclosed. By exposing a calibration substrate to ultraviolet light, a reaction is triggered that results in the cleaning of the contaminants from the calibration substrate. For instance, monatomic oxygen is introduced to contaminants on the surface of a calibration substrate to remove the contaminants without inducing modifications in the substrate itself. Through the cleaning process, the temperature of the calibration substrate may be controlled to limit adverse effects caused by the overheating of the calibration substrate.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 62/063,232, filed Oct. 13, 2014, the entirety of which is incorporated herein by reference. 
     
    
     INTRODUCTION 
       [0002]    In the ongoing struggle to keep up with the torrid pace set for integrated circuit (IC) manufacturers by Moore&#39;s Law, it is necessary to ensure that quality and process control tools and systems are able to keep up with the increasingly more complex and capable IC processing tools used for deposition, lithography, developing, and the like. One way that process control engineers ensure that their process tools are operating properly is to measure their semiconductor product substrates on which IC devices are formed. And, to ensure that the metrology systems used to measure process tool performance is up to acceptable standards, it is useful to continually monitor the operation of those metrology systems. 
         [0003]    Rather than using product wafers to verify calibration of metrology systems, it is the practice of semiconductor manufacturers to use calibration substrates that have some or all of the features of the product substrates that are being measured. While many different types of substrates, structures, layers, materials, and processes are monitored, for the purposes of this description, the metrology of thin film gate oxides, a structure familiar to those skilled in the art, will be used as an example for this discussion. A calibration substrate for monitoring the functionality of metrology systems, e.g. ellipsometers, used in turn to monitor the process tools may include a silicon wafer on which a uniform layer of a gate oxide is deposited. Metrology systems continually measure one or more calibration substrates to ensure that each metrology system remains both accurate and precise in its operation. It is common practice to utilize a single calibration wafer with multiple metrology systems, thereby ensuring that the respective systems all match one another to within a predetermined specification. 
         [0004]    Over time, hydrocarbon contamination or other types of contamination may be deposited on the surface of a calibration substrate. The contamination may be caused by nearby machines, ventilation systems, vapor emitting materials, or even from the exhalations of operators that manage the facility. Such types of contamination are fairly endemic in the semiconductor fabrication field and can make it difficult to determine whether anomalous measurements are due to drift in the settings of a metrology tool or due to increased contamination. Accordingly, it is a common practice to clean calibration substrates to reduce variation in the structures formed on a calibration wafer. 
         [0005]    Cleaning of calibration substrates, however, can have negative effects on the properties of a calibration substrate. Most cleaning systems in everyday use have the counterintuitive effect of modifying the calibration substrates, the very thing that is to be avoided. For example, solvent based cleaning systems may leave a residue on the surface of a calibration substrate. Thermal-type cleaning systems using infrared, microwave or other high energy cleaning techniques to heat a substrate to desorb hydrocarbon contamination may actually promote the growth of gate oxide layers on a calibration substrate due to increased diffusion of oxygen through the existing gate oxide layer to the surface of the calibration wafer. 
         [0006]    Metrology systems of many types, such as ellipsometers, use lasers and other optical sources to measure characteristics of substrates, both product and calibration. The energy of these optical sources can itself cause variation in a substrate where the heat imparted to the substrate by the metrology tool induces an advanced rate of oxide growth in the test site. Such growth may be particularly evident in those sites on a calibration substrate that are measured repeatedly using high energy illumination. Similarly, some manufacturers prepare a calibration substrate  10  for measurement using high intensity lasers to locally ablate contaminations at the site of a planned measurement. Repeated use of such ablation systems can create local variation in the calibration substrates that necessitate repeated measurements and premature replacement of the calibration substrate. 
       SUMMARY 
       [0007]    The present technology relates to a system for treatment of calibration substrates. The system involves identifying a discrepant datum or trend in measurement data obtained by a measuring tool. A calibration check or measurement is then conducted. Before the calibration proceeds, however, it is helpful to first clean the calibration substrate. Cleaning includes directing ultraviolet (UV) light at a wavelength of between approximately 185 nm and 254 nm to the surface of the calibration substrate at a power sufficient to remove substantially all molecular airborne contaminants from the surface of the calibration substrate. The goal, generally, is to clean the substrate without raising its temperature above approximately 50° C. Once clean, the calibration substrate is measured to determine whether the discrepant datum or trend in the measurement data was due to an anomaly in the measuring tool. It is also possible, however, that the discrepant datum or trend may be derived from the measurement of calibration substrates or product substrates. 
         [0008]    Because it is important to ensure that there is a proper correlation between measurements taken from a calibration substrate and those from a product substrate, it is desirable to record at least one measurement of the calibration substrate taken on a plurality of measuring tools over a predetermined period of time. Similarly, measurements of product substrates taken on the same plurality of measuring tools over the same predetermined period of time are also recorded. Generally, the calibration substrates are cleaned a plurality of times over the same predetermined period of time. Based on differences identified between measurements taken from product and calibration substrates in view of the number of times the calibration substrates have been cleaned, one may establish a cleaning limit for calibration substrates to ensure that there is good correlation between measurements taken from calibration and product substrates. 
         [0009]    While the foregoing cleaning limit may be established for any metrology tool and cleaning combination, it is desirable to maximize usage of calibration substrates by employing a cleaning process in which UV light at a wavelength of between approximately 185 nm and 254 nm is directed to the surface of the calibration substrate at a power sufficient to remove substantially all molecular airborne contaminants from the surface of the calibration substrate without raising the temperature of the substrate above approximately 50° C. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    Non-limiting and non-exhaustive examples are described with reference to the following Figures. 
           [0011]      FIG. 1  illustrates a schematic cross section of a typical calibration substrate having an oxide layer and a molecular airborne contaminant layer formed thereon. 
           [0012]      FIG. 2  illustrates the calibration substrate of  FIG. 1  having an improperly thick oxide layer formed thereon. 
           [0013]      FIG. 3  illustrates a schematic representation of a system for cleaning a calibration substrate. 
           [0014]      FIG. 4  illustrates an example method for cleaning a calibration substrate. 
           [0015]      FIG. 5  illustrates an example method for production controls incorporating a calibration process. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    In the following detailed description of the present technology, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments and examples in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention. Specifically, in the interests of brevity, this description will discuss a single type of calibration substrate that is used to verify measurements of a specific type of product substrate as an example for a broader range of different product types, process environments, and substrates. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims and equivalents thereof. 
         [0017]    Calibration wafers such as that shown in  FIGS. 1 and 2  are intended to represent the structures that are to be formed on a product wafer (not shown). The structures formed on a calibration wafer are not typically identical to those formed on a product wafer but, by design, there is intended to be good correlation between the measured features of calibration and product substrates. The manufacturer in this instance may then rely upon measurements taken from calibration substrates as signifying that measurements taken from a product wafer will be of a similar quality. Where one receives what is considered to be a “good” measurement from a measuring tool addressed to a calibration wafer, then one can reasonably presume that a measurement taken from a product wafer with the same measuring tool will be similarly acceptable. 
         [0018]      FIG. 1  depicts a schematic cross section of a typical calibration substrate  10  having an oxide layer  16  and a molecular airborne contaminant layer  18  formed thereon. The calibration substrate  10  shown in  FIG. 1  includes a silicon body  12  on which may optionally be deposited various structures, layers, or materials common to the semiconductor field, as indicated by optional layer  14 . The body of the substrate  10  may be made of other materials known to those skilled in the art as necessary for the particular implementation. An oxide layer may also be formed on the optional portion  14  of the substrate  10 . In other examples, the oxide layer  16  may be formed directly on the body  12  of the substrate. As will be familiar to those skilled in the art, molecular airborne contaminants (MACs) will come to rest on the otherwise clean surface of the oxide layer  16 , as indicated by the MAC layer  18 . This MAC layer  18  is undesirable as it is not intended to form a part of a semiconductor device and is observable to many measuring tools commonly used in semiconductor fabrication processes, such as ellipsometers for measuring thin film thicknesses among others. Because MACs are observable to measuring tools, the MACs can negatively affect calibration measurements taken from calibration substrates  10 . The presence of a MAC layer  18  reduces the correlation between the calibration and product substrates. 
         [0019]    Calibration substrates  10  differ from product substrates in that they are continually used for extended period of times and as a result, they are subject to higher levels of MAC contamination and other processes that can modify, change or even damage the calibration substrates. Product substrates are typically passed through a fabrication process with a minimum of exposure to the ambient environment, contaminants, or extraneous processes that are not directly tied to completing the structure of the IC devices contained therein. Because calibration wafers are subject to a higher degree of contamination, they are typically cleaned fairly frequently, either programmatically or when an anomalous measurement is obtained from the calibration or product substrate. As such, any adverse effects caused from cleaning may be compounded with each cleaning. 
         [0020]      FIG. 2  illustrates one example of what may occur as a result of frequent cleanings of calibration substrates. As can be seen, the post-cleaning oxide layer  16 ′ deposited on the calibration substrate  10  is much thicker than that shown in  FIG. 1 . As will be appreciated by those skilled in the art, repeated high temperature cleaning processes elevate the temperature of the calibration substrate  10  and increase the diffusion of ambient air, and particularly the oxygen in ambient air, to the surface of the silicon base  12 . At these elevated temperatures, the formation rate of the oxide layer is increased for a period of time. Over time and with repetition of the cleaning process, the post-cleaning oxide layer  16 ′ on the silicon base  12  will grow to a point where it no longer accurately corresponds, for example, to an oxide layer formed on a product substrate. Because a calibration that takes place in a range that is generally the same as the range of measurements that are to be used on product wafers is both desirable and advantageous, a calibration substrate  10  with an over-thick post-cleaning oxide layer  16 ′ may be discarded in favor of a new calibration substrate  10  with a more compliant oxide layer  16  thickness. It is therefore desirable to minimize variation to calibration substrates  10  due to phenomena such as increased oxide growth resulting from high temperature cleaning cycles. 
         [0021]      FIG. 3  illustrates schematically one example of a cleaning system  30  according to the present cleaning technology. An enclosure  32  includes a substrate support  34  and a source  36  of electromagnetic radiation  36 , such as UV light. The support  34  may be a top plate or chuck of any suitable arrangement or may be comprised of a set of lift pins (not shown) that limit direct contact with reverse side of the calibration substrate  10 . The support  34  may be provided with vacuum clamping mechanisms of a known type to ensure that the calibration substrate  10  does not move during exposure. In some examples, a supply  38  of cooling gases is provided, but the supply of cooling gases is not necessary. The calibration substrate  10  is placed on the substrate support  34  by known means, i.e. by a robot or similar substrate handler and the MAC layer  18  is removed by the action induced by UV radiation incident on the MAC layer  18 . UV radiation from the source  36  is incident upon oxygen molecules in the gases present in the enclosure  32  or in the MAC layer  18  itself, which converts some portion of the oxygen to ozone. Additional UV radiation converts some portion of the ozone into oxygen and monatomic oxygen (O), which is highly reactive with the type of hydrocarbons that typically form the MAC layer  18 . Reactions between the monatomic oxygen and the MAC layer  18  remove and or release from the substrate the materials that form the layer  18 . In some examples, the by-products of this reaction are removed by the flow of cooling gases from the supply  38 . Note that in some examples the cooling gas is filtered ambient air and, in other examples, the cooling gas is a gas that does not react readily with organic materials, such as nitrogen or a suitable noble gas. 
         [0022]    As one example, short wavelength UV light in the range of about 184-254 nm is sufficient to generate ozone and monatomic oxygen as described above. The source  36  may therefore be selected to output light in at least the wavelength range of about 184-254 nm. One suitable source is a mercury vapor lamp. The dose of UV light necessary to desorb substantially the entire MAC layer  18  is variable and depends on the nature and thickness of the MAC layer  18 . In one embodiment, it is sufficient to expose a calibration substrate  10  to the UV source  36  for approximately 50 seconds. This exposure, depending on the nature of the MAC layer  18 , is sufficient to remove a MAC layer  18  of approximately 3-5 angstroms in thickness. Note that if successive measurements remain anomalous, repeated exposures of the calibration substrate  10  to the UV source  36  are typically sufficient to fully desorb the MAC layer  18 . This additional treatment is useful to eliminate a MAC layer  18  as a cause of an anomalous measurement. 
         [0023]    In examples where a mercury vapor lamp is used as a UV source  36 , it may be useful to preheat the lamp to vaporize the mercury in the lamp to ensure that full radiant power is obtained from the source  36  during exposure of the calibration substrate  10 . Where other UV light sources such as light-emitting diodes (LEDs), lasers, or arc lamps are used, pre-heating may not be useful or necessary. The length of exposure of a calibration substrate  10  is at least partially inversely proportional to the power output by the source  36 . That is, the higher the power of the source  36 , the shorter the exposure time that is needed to clean the surface of the calibration substrate  10 . In the example illustrated in  FIG. 3 , a heater  40  is positioned adjacent to the source  36 . In one example, a resistive heater is applied to wall of the enclosure  32  to warm the source  36  in examples where the source is a lamp. Inclusion of the heater has an incidental effect of heating the ambient air temperature of the interior of the enclosure  32 . In some examples, the ambient air temperate in the interior of the enclosure may raise to approximately 80° C. Where a source  36  outputs a large amount of heat, radiant or conductive, it may be useful to provide a cooler (not shown) in lieu of a heater, depending on the requirements of the particular application. 
         [0024]    During exposure of a calibration substrate  10  to UV light emitted from the source  36 , the temperature of the calibration substrate  10  is also raised from its base temperature, which is usually around 20°-25° C. (i.e., ambient temperatures). In some examples, the temperature of the calibration substrate  10  is raised to a temperature between about 40°-50° C. Some of this temperature rise is due to the elevated temperature in the enclosure  32 . By keeping the substrate at low temperatures, such as within the range of 40°-50° C., the undesirable formation of oxides discussed above is reduced or prevented. The reduction of oxide formation is due in part to the lowness of the temperature because diffusion of oxygen to the base  12  of the calibration substrate  10  is limited at lower temperatures. Another factor contributing to the prevention of oxide formation is that calibration substrate  10  returns to ambient temperatures from its maximum temperature of between 40°-50° C. in a short period of time after exposure to the UV light. In short, any increase in diffusion is very modest and occurs over a very short period of time. As a result, cleaning of calibration substrate  10  using this technique does not modify the calibration substrate  10  in any meaningful way and more cleaning cycles can be undertaken. 
         [0025]    The cleaning system  30  may also include a controller  42  for controlling the processes and methods associated with the cleaning system  30 , as described herein. This is only one example of a suitable controller  42  and is not intended to suggest any limitation as to the scope of use or functionality. Other well-known computing systems, environments, and/or configurations that may be suitable for use as a controller and include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics such as smartphones, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like. 
         [0026]    In on example configuration, controller  42  typically includes at least one processing unit  44  and memory  46 . Depending on the exact configuration and type of controller  42 , memory  46  (storing, among other things, instructions for performing methods and processes as described herein) may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.), or some combination of the two. Memory  1704  may store computer-executable instructions that may be executed by the processing unit  44  to perform the methods disclosed herein. Further, the memory may be incorporated into one or more computer-readable storage devices including, but not limited to, solid-state, magnetic, or optical disks. The storage device should be understood to be a tangible device. In addition, the controller  42  may also have input device and output devices  48 , such as keyboard, mouse, pen, voice input, etc. and a display, speakers, printer, etc. Also included in the environment may be one or more communication connections  50  such as LAN, WAN, point to point, etc. 
         [0027]    The controller  42  may be a single computer operating in a networked environment using logical connections to one or more remote computers. The remote computer may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above as well as others not so mentioned. The logical connections may include any method supported by available communications media. The controller  42  may be connected physically or wirelessly to the metrology tools and the components of the cleaning system  30  in order to control the actions of the metrology tools and cleaning components. 
         [0028]    In practice, process engineers tasked with overseeing the production of IC devices monitor measurements of product substrates using selected metrology tools. Where an anomalous measurement is obtained there are generally two logical outcomes. First, the product substrate may be discrepant. Second, the metrology tool may be in error. Depending on the quality criteria set for the production of a particular IC device, a single anomalous measurement may be sufficient to require a calibration procedure for the metrology tool, though in other instances, a discrepant trend in measurements over time may be investigated. In either case, a calibration substrate  10  will be measured in lieu of a product substrate to determine whether the metrology tool is operating within specifications. To avoid an anomalous calibration measurement, one may clean the calibration wafer prior to its measurement using the methods described hereinabove. Where an anomalous calibration measurement is obtained, one may attempt to clean the calibration wafer a second or even a third time to ensure the removal of any MAC layers  18  that may induce measurement error. After a sufficient number of cleanings (one or more), an anomalous calibration reading may be confirmed and maintenance or adjustment of the metrology tool may be undertaken. 
         [0029]      FIG. 4  illustrates an example method  400  for cleaning a calibration substrate. While the methodology is shown and described as being a series of acts that are performed in a sequence, it is to be understood and appreciated that the methodology is not limited by the order of the sequence. For example, some acts can occur in a different order than what is described herein, as will be appreciated by those skilled in the art. In addition, some acts can occur concurrently with another act. Further, in some instances, not all acts may be required to implement a methodology described herein. Moreover, the acts described herein may be computer-executable instructions that can be implemented by one or more processors and/or stored on a computer-readable medium or media. The computer-executable instructions can include a routine, a sub-routine, programs, a thread of execution, and/or the like. Still further, results of acts of the methodology can be stored in a computer-readable medium, displayed on a display device, and/or the like. 
         [0030]    At operation  402 , the calibration substrate is inserted into a cleaning system, such as cleaning system  30  discussed above. In examples where the light source is a lamp that benefits from preheating, the lamp may be preheated at operation  404 . At operation  406 , the light source is applied to the calibration substrate for a period of time suitable for the particular calibration substrate. As discussed above, the light applied to the calibration substrate is generally within the UV range. The time period for which the light is applied may be predetermined through the use of experimental data or through empirical or theoretical analysis based on the composition of the calibration substrate, the wavelength of light applied, and the intensity of the light. In some examples, the light may be applied in a pulsed manner to prevent overheating the calibration substrate. In other examples, the temperature of the calibration substrate is monitored, and the exposure of the calibration substrate to the light is terminated when the temperature reaches a certain threshold. For instance, the exposure to the light may be terminated when the temperature monitoring indicates the calibration substrate may rise to temperature above 50° C. At operation  408 , a cooling gas may be applied such that the flow of the cooling gas removes by-products of the reaction caused by the exposure of light emitted from the light source. 
         [0031]    At operation  410 , the calibration substrate is measured by the metrology tools. Based on the measurement of the calibration substrate, it is determined if the measurements are within the expected tolerances for the calibration substrate at operation  412 . If the measurements are not within the expected tolerances, the measurement may still be an anomalous calibration measurement due to MACs on the calibration substrate. Such an anomalous calibration measurement may be identified as a discrepant datum. As such, the method flows back to operation  404 , where the cleaning process of the calibration substrate is performed again. If anomalous calibration measurements continue to be obtained at operation  412 , the cleaning process may be repeated for a predetermined number of times before a determination is made that the metrology tools need to be recalibrated. If however, the measurements made at operation  410  are determined to be within the expected tolerances, an indication is presented that the metrology tools are properly calibrated at operation  414 . 
         [0032]      FIG. 5  illustrates an example method  500  for production controls incorporating a calibration process. At operation  502 , a product substrate is measured using measuring tools, such as metrology tools. At operation  504 , those measurements are analyzed to determine if there is an anomaly in the product substrate. Such an anomaly may be identified as a discrepant datum. If the measurements indicate that the product substrate is not anomalous, production continues at operation  506  and the next product substrate is analyzed. If, however, the measurements indicate that the product substrate is anomalous, a calibration process is performed at operation  508 . The calibration process may be calibration and cleaning method  400  described above with reference to  FIG. 4 . At operation  510 , based on the calibration process performed at operation  508 , it is determined whether the metrology tools used to analyze the product substrate are properly calibrated. If the metrology tools are not properly calibrated, the metrology tools are recalibrated at operation  512 , and the calibration process is performed again to ensure that the metrology tools have been properly recalibrated. If, however, the metrology tools are determined to be properly calibrated at operation  510 , an indication is generated that indicates the product substrate has a defect at operation  514 . In some examples, the product substrate is removed from production at operation  516 . The product substrate may be removed from production for further analysis to determine whether the entire substrate should be discarded, or if a portion of the substrate can be recovered. 
         [0033]    Based on a plurality of recorded measurements of calibration substrates and product substrates, a limit on the number of cleanings may be established. While the cleaning processes described herein have a minimal effect of the cleaning substrate, there may be minimal adverse effects that compound over time. As such, it may be useful to establish a preferred limit of cleanings for each calibration substrate. 
         [0034]    While various examples were provided above, the present invention is not limited to the specifics of the examples. The calibration substrate cleaning arrangements described herein may be used alone or in conjunction with other metrology or processing tools or equipment. Furthermore, the cleaning arrangements described herein may be used with items other than calibration substrates. Because the measurements of the calibration substrate and the product substrates should be substantially the same, a difference criterion or limit may be established to indicate when the calibration substrate is no longer an accurate correlation substrate for the product substrate, despite being substantially free of MACs. For instance, if the measurements of the calibration substrates and the product substrates are no longer within a 1% tolerance despite recent cleaning of the calibration substrate, the difference criterion will have been determined to be exceeded. At that point, the number of cleanings performed on the particular calibration substrate may be determined, and that number of cleanings may be established to be the limit of cleanings for calibration substrates. 
         [0035]    Although specific embodiments of the present invention have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown. Many adaptations of the invention will be apparent to those of ordinary skill in the art. For instance, those having skill in the art will appreciate that while the cleaning techniques described herein are primarily discussed with reference to cleaning a calibration substrate, the cleaning techniques may also be used to clean a product substrate. Accordingly, this application is intended to cover any adaptations or variations of the invention. It is manifestly intended that this invention be limited only by the following claims and equivalents thereof.