Haze mask system for haze suppression

This system and method minimize an effect of haze to signal-to-noise ratio and compensate for haze on the haze map. A first mask with a first aperture is disposed along the path of the light beam between a light source and a collector. A first actuator moves the first mask along a tangential direction. A second mask with a second aperture is disposed along the path of the light beam between the first mask and the collector. A second actuator moves the second mask along a radial direction perpendicular to the tangential direction. The first mask and the second mask are independently movable along the tangential direction and the radial direction using the first actuator and the second actuator.

FIELD OF THE DISCLOSURE

This disclosure relates to haze suppression during imaging.

BACKGROUND OF THE DISCLOSURE

Evolution of the semiconductor manufacturing industry is placing greater demands on yield management and, in particular, on metrology and inspection systems. Critical dimensions continue to shrink, yet the industry needs to decrease time for achieving high-yield, high-value production. Minimizing the total time from detecting a yield problem to fixing it determines the return-on-investment for a semiconductor manufacturer.

Metrology processes are used at various steps during semiconductor manufacturing to monitor and control the process. Metrology processes are different than inspection processes in that, unlike inspection processes in which defects are detected on wafers, metrology processes are used to measure one or more characteristics of the wafers that cannot be determined using existing inspection tools. Metrology processes can be used to measure one or more characteristics of wafers such that the performance of a process can be determined from the one or more characteristics. For example, metrology processes can measure a dimension (e.g., line width, thickness, etc.) of features formed on the wafers during the process. In addition, if the one or more characteristics of the wafers are unacceptable (e.g., out of a predetermined range for the characteristic(s)), the measurements of the one or more characteristics of the wafers may be used to alter one or more parameters of the process such that additional wafers manufactured by the process have acceptable characteristic(s).

In the semiconductor industry, the term haze can be used to describe the micro-roughness of a wafer surface. This can be a useful parameter for both integrated circuit and wafer manufacturers. Background scatter caused by imperfections on the surface of the substrate, such as intrinsic substrate roughness and polishing damage, leads to haze. Haze has been shown to correlate to a broad array of process parameters, such as surface roughness, grain size, and process temperature.

Many metrology tools and other tools in the semiconductor industry include an ultraviolet (UV) channel and an additional second wavelength or dual wavelength (DW) channel with a longer wavelength to detect the embedded defects within the photo-resistors or multi-layered structure for memory. For example, a longer wavelength of 488 nm may be used. There is no effective way to suppress the haze with the UV channel. Therefore, new techniques and systems to suppress haze are needed.

BRIEF SUMMARY OF THE DISCLOSURE

A system is provided in a first embodiment. The system comprises an illumination subsystem that generates a light beam, a stage configured to hold a wafer in a path of the light beam, a collector in the path of the light beam, a first mask disposed along the path of the light beam between the light source and the collector, a first actuator that moves the first mask along a tangential direction, a second mask disposed along the path of the light beam between the first mask and the collector, and a second actuator that moves the second mask along a radial direction perpendicular to the tangential direction. The first mask defines a first aperture. The second mask is fabricated of metal and defines a second aperture. The first mask and the second mask are independently movable along the tangential direction and the radial direction, respectively, using the first actuator and the second actuator to minimize an effect of haze to signal-to-noise ratio.

The system can include a processor in electronic communication with the first actuator and the second actuator. The processor can be configured to determine a haze map of the wafer and send instructions to at least one of the first actuator and the second actuator to move at least one of the first mask or the second mask.

In an instance, the processor is further configured to send instructions to the second actuator to sweep the second mask over a range, monitor signal-to-noise ratio and haze values, and determine an optimal position for the second mask that minimizes the effect of haze to signal-to-noise.

In an instance, the processor is further configured to send instructions to the first actuator to sweep the first mask over a range, monitor signal-to-noise ratio and haze values, and determine an optimal position for the first mask that minimizes the effect of haze to signal-to-noise.

The first actuator may include a mask change wheel.

The first mask may be disposed on a mask change wheel. The mask change wheel can include a plurality of other masks.

A method is provided in a second embodiment. The method comprises disposing, using a first actuator, a first mask at a first position along a path of a light beam between a light source and a collector. The first mask defines a first aperture. Using a second actuator, a second mask is disposed at a second position along the path of the light beam between the first mask and the collector. The second mask is fabricated of metal. The second mask defines a second aperture. The first position and the second position minimize an effect of haze to signal-to-noise ratio.

Disposing the first mask may be independent of disposing the second mask.

In an instance, a haze map of the wafer is determined using a processor. Instructions are sent, using the processor, to at least one of the first actuator and the second actuator to move at least one of the first mask or the second mask to compensate for haze on the haze map.

In an instance, instructions can be sent from the processor to the second actuator to sweep the second mask over a range. Using the processor, the signal-to-noise ratio and haze values are monitored. Using the processor, an optimal position for the second mask that minimizes the effect of haze to signal-to-noise can be determined.

In an instance, instructions can be sent from the processor to the first actuator to sweep the first mask over a range. Using the processor, the signal-to-noise ratio and haze values can be monitored. Using the processor, an optimal position for the first mask that minimizes the effect of haze to signal-to-noise can be determined.

Disposing the first mask may include moving the first mask in a tangential direction.

Disposing the second mask may include moving the second mask in a radial direction perpendicular to the tangential direction.

DETAILED DESCRIPTION OF THE DISCLOSURE

To detect embedded defects, such as those in a 3D NAND film stack (e.g., an ONON stack), an additional channel with a particular wavelength or DW channel, besides the UV channel, can be used. To achieve better sensitivity, tighter haze control is needed to minimize negative haze impact and improve signal-to-noise ratio. As seen in the example shown inFIG. 1, the haze in the exemplary haze map is not insignificant. However, there is usually residual alignment error for both illumination and collection, and the resultant haze distribution may vary from tool to tool as the typical haze map shown inFIG. 1, where the hot spots are shifted to the right side. A haze map is far field projection of intrinsic haze of a wafer when it is illuminated with certain of certain spot size and wavelength. Ideally, the hot spots on the haze map formed as the result of larger tangential illumination numerical aperture are centered on the map.

A dynamic and reconfigurable haze mask combination that uses two masks is disclosed in the embodiments herein. An embodiment of a system100is shown inFIG. 2. The system100includes an illumination subsystem104that generates a light beam111to illuminate defects on a wafer113and scattering light from the wafer. The system100also includes a stage114configured to hold the wafer113in a path of the light beam111. WhileFIG. 2illustrates the light beam111as passing through the wafer113in a linear manner, the light beam111may be projected at the wafer113at an angle and reflected from the wafer113at an angle toward the first mask101. The system100also includes a collector103. The collector103is in the path of the light beam111. The collector103can include one or more lenses and a sensor.

For UV channels, a P-lens is not present, which is pneumatically actuated. For DW channel, a P-lens116is present. All lenses inFIG. 2may have a dual band antireflective coating for UV and DW. There is no impact to haze mask. For haze mapping, both slits from first mask101and second mask102are mechanical slits, and they are wavelength independent.

A first mask101is disposed along the path of the light beam111between the illumination subsystem104and the collector103. The first mask101defines a first aperture. The first mask101can be fabricated from a steel sheet. For example, the first mask101may be a302stainless steel sheet.

A first actuator105moves the first mask101in the tangential direction (as seen inFIG. 1). The first actuator can be a mask change wheel. Any angular position for the first mask101can be obtained using the first actuator105. The first actuator105can provide an acceptable level of precision. In an instance, the first actuator105is a stepper motor with an encoder.

In an instance, the first mask101is disposed on a mask change wheel. The first mask101is one of several masks on the mask change wheel. The mask change wheel can select a mask that provides optimized haze reduction. The masks on the mask change wheel, including the first mask101, can be used for a DW channel.

FIG. 3is a perspective view of an embodiment of the first mask101ofFIG. 2. The first mask101is part of the mask change wheel108. The first mask101includes a first aperture109, which in this instance is circular. Other shapes are possible. The other masks on the mask change wheel108include apertures with different shapes (e.g., polygonal, arcuate, etc.). While eight masks are illustrated in the mask change wheel108, more or fewer masks are possible. In an instance, ten masks are included on the mask change wheel.

Regarding the mask change wheel108, the different sizes and shapes of masks can be combined with the first mask101. The various masks in the mask change wheel108can be formed from a thin metal sheet, such as a steel sheet.

An extra haze mask on the mask changer may be fixed to the place holder of the mask changer. Thus, impact to the UV channel can be minimized.

Turning back toFIG. 1, a second mask102is disposed along the path of light beam111between the first mask101and the collector103. Relay lenses115may be disposed between the first lens101and the second lens102. Four of the relay lenses are illustrated, but other numbers are possible. The second mask102is fabricated of metal and defines a second aperture. For example, the second mask102may be fabricated of302stainless steel. The number of apertures in the second mask102can vary. More of fewer apertures than illustrated herein are possible. Thus, the second mask102may have only one aperture.

The second mask102may be an oversize of the original mirror made from fused silica. The second mask102can keep most of area open to remove the impact to UV. However, to achieve the haze mapping for both UV and DW, a mechanical slit can be formed to overlap with original coated slit on mirror. At the same time, an additional mask is formed to block haze. The additional mask is an elliptical disk in this instance.

In an instance, the second mask102includes a thin metal sheet that is overlapped and fixed to a mirror. This can reduce negative effects to the UV channel. The mirror may be held down by a retainer frame. The metal sheet can be added between the mirror and the retainer frame. Thus, the metal sheet can be held between the mirror and the retainer frame.

FIG. 4is a perspective view of an embodiment of the second mask102ofFIG. 2. The second mask102can include a second aperture110in a mirror. As seen inFIG. 4, the second mask102can include an oval mask and a slit mask. The oval mask and the slit mask can be formed in the same piece. The second mask102can enable the haze mapping for both UV and DW.

Regarding the mirror, there can be a mechanical slit on the second mask102. It should be aligned with optical slit formed with coating on the mirror to allow both UV and DW light to pass through to enable haze mapping for both UV and DW. The elliptical disk mask may be positioned so that it locates in the unoccupied area of UV and can be movable by motorized actuation.

Turning back toFIG. 1, a second actuator106moves the second mask102along a radial direction perpendicular to the tangential direction (as seen inFIG. 1). The second actuator106can move the second mask102along a whole length of its mirror with an acceptable level of precision. In an instance, the second actuator106includes two pneumatic cylinders that operate in opposite directions.

The first mask101and the second mask102are independently movable along the radial direction (e.g., direction112) and the tangential direction (e.g., perpendicular to direction112, such as going into the page) using the first actuator105and the second actuator106. The radial direction also may extend in other directions, and direction112is only one example. Thus, the first mask101and second mask102are dynamic and reconfigurable for different wafers or applications to adapt to the different offsets of hot spots of haze that result from residual alignment errors and intrinsic properties of different wafers.

The first mask101and the second mask102can be positioned along the tangential direction and radial directions independently, so haze with shifted hot spots can be compensated for by reconfiguring the position of the first mask101and the second mask102to minimize the detrimental effect of haze to signal-to-noise ratio and to improve the sensitivity.

Natural variation of haze “hot spots” can shift between tools, such as metrology tools. To suppress the haze, dynamic and adaptive haze masks with particular sizes and shapes can be used. The first actuator105and second actuator106can independently provide radial motion of second mask102and tangential motion of the first mask101. The second mask102and first mask101may be considered conjugated, and the combination of independent first mask101and second mask102can be adaptive to different haze distributions of different tools by selecting the mask shape and size for the first mask101and second mask102.

To reduce impact of two extra masks to original UV channels, a desired pattern is cut from a thin metal sheet, and it is overlapped with a mirror to form the second mask102. In addition, the original slit formed by dedicated design of coating for UV channel may not be effective for DW because the slit on the mirror may be formed with an optical coating for UV. The optical coating may be transparent at DW, which means the optical coating cannot be used to map haze for DW. Thus, mapping haze for DW may be difficult without the second mask102. As shown inFIG. 2, the first mask101and second mask102are combined together, which reduces impact to UV channels. The size of the haze mask can be configured to block the possible “hot spots” of haze, and its location can be motorized control to cover both “hot spots.”

Considering a haze profile derived from haze map can be different for a bare silicon wafer and a semiconductor manufacturer's wafer, different shapes and sizes of masks can be included for both the first mask101and the second mask102.

To determine an optimal location of the first mask101and second mask102, a haze map for DW can be built by sweeping with the second mask102and the mask change wheel108switched to a slit. Then another mask on the mask change wheel108(such as the first mask101) is controlled to sweep over certain range by monitoring signal-to-noise ratio and haze value. For example, the sweep may be less than 1 mm. From this information, an optimal first mask101position can be determined. To determine optimal first mask101position, one or more of minimal haze, highest signal-to-noise, and maximized sensitivity may be evaluated. Shown inFIG. 5is one of example on how to search for the optimal position of second mask102. To determine optimal second mask102position, one or more of minimal haze, highest signal-to-noise (SNR), and maximized sensitivity may be evaluated. M1inFIG. 5represents the second mask102. By setting the second mask102to the optimal position, the similar procedure can be adopted for searching optimal position of the first mask101by sweeping the mask change wheel108over a certain range.

Turning back toFIG. 2, a processor107can be in electronic communication with the first actuator105and the second actuator106. The processor107also can be in electronic communication with the collector103. The processor107can be configured to determine a haze map of a wafer and send instructions to at least one of the first actuator105or the second actuator106to move at least one of the first mask101or the second mask102to compensate for haze on the haze map. Instructions to the first actuator105can move the first mask101. Instructions to the second actuator106can move the second mask102.

The processor107can be configured to send instructions to the second actuator106to sweep the second mask102over a range. The processor107then can be configured to monitor signal-to-noise ratio and haze values and determine an optimal position for the second mask102. The optimal position can compensate for haze on the haze map, such as by minimizing the effect of haze to signal-to-noise.

The processor107also can be configured to send instructions to the first actuator105to sweep the first mask101over a range. The processor107then can be configured to monitor signal-to-noise ratio and haze values and determine an optimal position for the first mask. The optimal position can minimize haze value and push signal-to-noise higher, which can result in better sensitivity, such as by minimizing the effect of haze to signal-to-noise.

The processor107may be coupled to the components of the system100in any suitable manner (e.g., via one or more transmission media, which may include wired and/or wireless transmission media) such that the processor107can receive output. The processor107may be configured to perform a number of functions using the output. The system100can receive instructions or other information from the processor107. The processor107optionally may be in electronic communication with a database, wafer inspection tool, a wafer metrology tool, or a wafer review tool (not illustrated) to receive additional information or to send instructions. For example, the processor107can be in electronic communication with a database that includes haze data for various wafers.

The processor107, other system(s), or other subsystem(s) described herein may be part of various systems, including a personal computer system, image computer, mainframe computer system, workstation, network appliance, internet appliance, or other device. The subsystem(s) or system(s) may also include any suitable processor known in the art, such as a parallel processor. In addition, the subsystem(s) or system(s) may include a platform with high-speed processing and software, either as a standalone or a networked tool.

The processor107may be disposed in or otherwise part of the system100or another device. In an example, the processor107may be part of a standalone control unit or in a centralized quality control unit. Multiple processors107may be used.

The processor107may be implemented in practice by any combination of hardware, software, and firmware. Also, its functions as described herein may be performed by one unit, or divided up among different components, each of which may be implemented in turn by any combination of hardware, software and firmware. Program code or instructions for the processor107to implement various methods and functions may be stored in readable storage media.

If the system100includes more than one processor107, then the different subsystems may be coupled to each other such that images, data, information, instructions, etc. can be sent between the subsystems. For example, one subsystem may be coupled to additional subsystem(s) by any suitable transmission media, which may include any suitable wired and/or wireless transmission media known in the art. Two or more of such subsystems may also be effectively coupled by a shared computer-readable storage medium (not shown).

The processor107may be configured to perform a number of functions using the output of the system100or other output. For instance, the processor107may be configured to send the output to a storage medium. The processor107may be further configured as described herein.

If the system includes more than one subsystem, then the different subsystems may be coupled to each other such that images, data, information, instructions, etc. can be sent between the subsystems. For example, one subsystem may be coupled to additional subsystem(s) by any suitable transmission media, which may include any suitable wired and/or wireless transmission media known in the art. Two or more of such subsystems may also be effectively coupled by a shared computer-readable storage medium (not shown).

The processor107may be configured according to any of the embodiments described herein. The processor107also may be configured to perform other functions or additional steps using the output of the system100or using images or data from other sources.

Various steps, functions, and/or operations of system100and the methods disclosed herein are carried out by one or more of the following: electronic circuits, logic gates, multiplexers, programmable logic devices, ASICs, analog or digital controls/switches, microcontrollers, or computing systems. Program instructions implementing methods such as those described herein may be transmitted over or stored on carrier medium. The carrier medium may include a storage medium such as a read-only memory, a random access memory, a magnetic or optical disk, a non-volatile memory, a solid state memory, a magnetic tape, and the like. A carrier medium may include a transmission medium such as a wire, cable, or wireless transmission link. For instance, the various steps described throughout the present disclosure may be carried out by a single processor107or, alternatively, multiple processors107. Moreover, different sub-systems of the system200may include one or more computing or logic systems. Therefore, the above description should not be interpreted as a limitation on the present disclosure but merely an illustration.

FIG. 6is a flowchart of an embodiment of a method200. At201, a first mask is disposed using a first actuator at a first position along a path of a light beam between a light source and a collector. The first mask defines a first aperture. At202, a second mask is disposed at a second position using a second actuator along the path of the light beam between the first mask and the collector. The second mask defines a second aperture and is fabricated of metal. The first position and the second position minimize an effect of haze to signal-to-noise ratio.

Disposing the first mask can be independent of disposing the second mask. Disposing the first mask can include moving the first mask in a tangential direction. Disposing the second mask can include moving the second mask in a radial direction perpendicular to the tangential direction.

In an instance, a haze map of the wafer is determined using a processor. Instructions are sent to at least one of the first actuator and the second actuator to move at least one of the first mask or the second mask to compensate for haze on the haze map.

In another instance, instructions can be sent from the processor to the second actuator to sweep the second mask over a range. Using the processor, the signal-to-noise ratio and haze values is monitored and an optimal position for the second mask is determined.

Instructions can be sent from the processor to the first actuator to sweep the first mask over a range. Using the processor, monitoring, using the processor, the signal-to-noise ratio and haze values are monitored and an optimal position for the first mask is determined.

In an example, a series of masks are added to the mask change wheel108with the first mask101to evaluate the impact of haze to signal-to-noise ratio. With certain masks using embodiments disclosed herein, the haze can be suppressed to almost30x and signal-to-noise ratio is improved. In an instance, the optimal combination can be achieved with a few iterative independent optimizations of the first mask and the second mask. The start points of the first mask and the second mask may be near one another at initial alignment.

With respect to the W2 UV channel, there are typically three channels for UV, W1, W2 and Narrow. The W2 UV channel is shown inFIG. 2, which is shared with DW channel.

The embodiments disclosed herein are teachable for tangential and radial directions, which makes the system adaptive to a variation of haze “hot spots” shift from tool to tool. Searching of an optimal position of the first mask101and the second mask102can be combined with initial calibration. The initial calibration can be performed once. Additional calibration may not be needed.

The embodiments of the first mask101and second mask102can be retrofitted onto existing tools.

Embodiments disclosed herein can solve the “high haze” issue of UV normal narrow channel, which has caused problems with previous systems. High haze refers to the haze value during the normal scan. The similar design can be used for a narrow channel. A UV narrow channel has suffered high haze and thus less desired sensitivity. This dynamic and adaptive haze mask has been proven to suppress the haze, improve signal-to-noise ratio, and sensitivity of DW. The resultant haze suppression and signal-to-noise ratio improvement is shown in the table ofFIG. 7. The table inFIG. 7shows the signal-to-noise improvement of a known defect size, which is shown in the left column with different combinations of masks disclosed herein. Information in the table can be used to determine effectiveness of a mask combination.

Each of the steps of the method may be performed as described herein. The methods also may include any other step(s) that can be performed by the processor and/or computer subsystem(s) or system(s) described herein. The steps can be performed by one or more computer systems, which may be configured according to any of the embodiments described herein. In addition, the methods described above may be performed by any of the system embodiments described herein.