Patent Publication Number: US-2022230834-A1

Title: Electron beam writing apparatus and cathode life span prediction method

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2021-8117, filed on Jan. 21, 2021 and No. 2021-206375, filed on Dec. 20, 2021, the entire contents of which are incorporated herein by reference. 
     FIELD 
     An embodiment of the present invention relates to an electron beam writing apparatus and a cathode life span prediction method. 
     BACKGROUND 
     In recent years, with the miniaturization of semiconductor devices, a shot size of an electron beam for forming a pattern on a mask has decreased. As the shot size decreases, the throughput of mask lithography decreases. In order to improve the throughput, it is necessary to increase the current density of an electron beam on a sample surface, and in order to increase the current density, it is necessary to increase an emission current carried through a cathode emitting an electron beam. 
     Since an increase in the emission current shortens the life span of the cathode, it is necessary to accurately predict when the cathode will reach its life span. Conventionally, the life span of the cathode is predicted by detecting the current distribution of an aperture and an emission current. However, in the conventional method, there is the case in which it is noticed that the cathode reaches its life span after the emission current rapidly decreases, and it is not possible to accurately predict the time at which the cathode reaches its life span in advance. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram showing a schematic configuration of an electron beam writing apparatus according to an embodiment; 
         FIG. 2  is a diagram showing an example of installation locations of an electron optical column and a plurality of detectors provided in a pattern generation chamber; 
         FIG. 3A  is a graph plotting a correspondence relationship between cathode conditions and beam characteristics; 
         FIG. 3B  is a graph plotting a correspondence relationship between the time at which the amount of fluctuation in  FIG. 3A  is obtained and the amount of fluctuation; 
         FIG. 4  is a flowchart showing a function generation procedure in a first prediction method; 
         FIG. 5A  is a graph plotting a correspondence relationship between cathode conditions and beam characteristics; 
         FIG. 5B  is a graph plotting a correspondence relationship between the time at which the amount of fluctuation in  FIG. 5A  is obtained and the amount of fluctuation; and 
         FIG. 6  is a flowchart showing a function generation procedure in a second prediction method. 
     
    
    
     DETAILED DESCRIPTION 
     In the following, an embodiment of an electron beam writing apparatus and a cathode life span prediction method will be described with reference to the drawings. In the following, although the main components of the electron beam writing apparatus and the cathode life span prediction method will be mainly described, the electron beam writing apparatus and the cathode life span prediction method may have components and functions that are not shown or described. The following description does not exclude components and functions that are not shown or described. 
       FIG. 1  is a block diagram showing a schematic configuration of an electron beam writing apparatus  2  according to an embodiment. The electron beam writing apparatus  2  in  FIG. 1  includes a pattern generator  3  and a controller  4 . The pattern generator  3  draws a desired pattern on a sample. The controller  4  controls the pattern generator  3 . 
     The pattern generator  3  has an electron optical column  5  and a pattern generation chamber  6 . In the inside of the electron optical column  5 , an electron gun  7 , an illumination lens  8 , a blanking deflector  9 , a blanking aperture  10 , a first shaping aperture  11 , a shaping lens  12 , a shaping deflector  13 , a second shaping aperture  14 , a reducing glass  15 , an objective lens  16 , a secondary deflector  17 , and a primary deflector  18  are provided. In the inside of the pattern generation chamber  6 , an XY stage  19  movably disposed is provided. The XY stage  19  is provided with a beam absorbing electrode (Faraday cup)  20  that measures the current of an electron beam to be applied. On the XY stage  19 , a sample that is a target for pattern generation is placed. The sample is a mask substrate for exposure that transfers a pattern to a semiconductor wafer. With the use of the semiconductor wafer as a sample, a pattern may be directly written on the semiconductor wafer. The electron gun  7  has a cathode  21  and an anode  22 . The cathode  21  has an emitter  23 , a Wehnelt electrode  24 , and a pair of filaments  25 . Across the pair of filaments  25 , a high voltage is applied. The emitter  23  is connected to one end of each of the pair of filaments  25 . The Wehnelt electrode  24  is disposed opposite to the emitter  23 . The anode  22  is grounded. 
     The controller  4  has an electron gun controller  31  and a pattern generation controller  32 . The electron gun controller  31  has a constant current source  33 , a variable voltage source  34 , an ammeter  35 , a voltmeter  36 , and a drive controller  37 . The constant current source  33  carries a predetermined heating current to both poles of the emitter  23 . The variable voltage source  34  applies a predetermined bias voltage (Wehnelt voltage) across the intermediate voltage node of both poles of the emitter  23  and the Wehnelt electrode  24 . The ammeter  35  is connected to one end side of the variable voltage source  34  through a DC voltage source  38 . The ammeter  35  measures an emission current carried through the cathode  21 . In addition, the voltmeter  36  is connected in parallel to the variable voltage source  34 . The voltmeter  36  measures the bias voltage (Wehnelt voltage) described above. The drive controller  37  monitors the measurement results of the ammeter  35  and the voltmeter  36 , and controls the variable voltage source  34  based on the output signal of the pattern generation controller  32 . 
     The pattern generation controller  32  has a current density measurement unit  41  and a PID controller  42 . The current density measurement unit  41  measures the current density of a sample surface. The PID controller  42  calculates the target value of the emission current based on the current density of the sample surface measured by the current density measurement unit  41 . The calculated target value is sent to the drive controller  37 . The drive controller  37  controls the variable voltage source  34  based on the target value received from the PID controller  42 . More specifically, the drive controller  37  performs the feedback control of the bias voltage based on the target value. 
     The PID controller  42  has a condition controller  43  and a prediction unit  44 . The condition controller  43  changes a plurality of conditions (in the following, also referred to as a cathode condition) that emits an electron beam from the cathode  21 . The cathode condition includes, for example, at least one of an emission current carried through the emitter  23 , a bias voltage applied to the filament  25 , filament power supplied to the filament  25 , and a temperature of the filament  25 . 
     The prediction unit  44  predicts the life span of the cathode  21  based on a temporal change in the amount of fluctuation of the beam characteristic of the electron beam to a variation in the cathode condition when the cathode condition is changed in a plurality of ways. The temporal change in the amount of fluctuation of the beam characteristic refers to the amount of fluctuation of the beam characteristic in the minimum unit of control of the high-voltage power supply that supplies power to the cathode  21 . Specifically, a temporal change in the amount of fluctuation of the beam characteristic includes at least one of the amount of transmitted electrons of the aperture, the amount of the current of reflected electrons, the amount of the current of secondary electrons, and a variation in the bias voltage applied to the filament  25  of the cathode  21 . 
     The prediction unit  44  predicts the life span of the cathode  21  based on, for example, a temporal change in the amount of fluctuation of the beam characteristic to a variation in the cathode condition. In this case, the PID controller  42  may have a function generator  45 . The function generator  45  generates a function that obtains a temporal change in the amount of fluctuation of the beam characteristic of the electron beam to a change in the cathode condition at an arbitrary time based on a temporal change in the amount of fluctuation of the beam characteristic of the electron beam to a change in the cathode condition at each of the plurality of times. The prediction unit  44  determines that the life span of the cathode  21  reaches the time at which a temporal change in the amount of fluctuation of the beam characteristic of the electron beam to a change in the cathode condition obtained by the function becomes a predetermined threshold. 
     Here, in the case in which a temporal change in the amount of fluctuation of the beam characteristic is represented by an absolute value, the prediction unit  44  determines that the life span of the cathode  21  is reached at a time at which a temporal change in the amount of fluctuation becomes equal to or greater than a predetermined threshold. In addition, in the case in which a direction in which a temporal change in the amount of fluctuation becomes larger is a positive value, it is determined that the life span of the cathode  21  is reached at a time at which a temporal change in the amount of fluctuation becomes equal to or greater than a predetermined threshold. On the other hand, in the case in which the direction in which a temporal change in the amount of fluctuation becomes larger is a negative value, it is determined that the life span of the cathode  21  is reached at the time at which a temporal change in the amount of fluctuation becomes equal to or less than the predetermined threshold. 
     Alternatively, the prediction unit  44  may predict the life span of the cathode  21  based on a temporal change in the amount of fluctuation of the beam characteristic when the cathode condition is changed. In this case, the function generator  45  in the PID controller  42  generates a function that obtains the absolute value of the amount of fluctuation of the beam characteristic when the condition is changed at each of the plurality of times. The prediction unit  44  determines that the life span of the cathode  21  is reached at the time at which the amount of fluctuation of the beam characteristic obtained by the function becomes the threshold. 
     At a plurality of places of the electron optical column  5  and the pattern generation chamber  6 , a plurality of detectors  46  is provided.  FIG. 2  is a diagram showing an example of installation locations of the electron optical column  5  and the plurality of detectors  46  provided in the pattern generation chamber  6 . In the example in  FIG. 2 , the detector  46  is provided on each of the blanking aperture  10 , the first shaping aperture  11 , the second shaping aperture  14 , and the lower surface side of the objective lens  16  in the electron optical column  5 , and the detector  46  is also provided on the sample surface. The detector  46  in the electron optical column  5  detects the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons in each aperture. The detector  46  on the sample surface detects the amount of the current of reflected electrons or secondary electrons on the sample surface. The prediction unit  44  detects a temporal change in the ratio of the amount of fluctuation of the beam characteristic based on the detection currents of the detectors  46 . 
     Each of configurations or functions of the controller  4  may be configured by hardware such as circuitry or may be configured by software. When the functions are configured by the software, a program for realizing at least a part of the functions of the controller  4  may be stored in a recording medium such as a CD-ROM and read and executed by a computer. The recording medium is not limited to a detachable recording medium such as a magnetic disk or an optical disk and may be a fixed recording medium such as a hard disk device or a memory. 
     The prediction unit  44  described above predicts the life span of the cathode  21  in advance by, for example, a first prediction method or a second prediction method. In the following, the first prediction method and the second prediction method will be sequentially described. 
     First Prediction Method 
       FIGS. 3A and 3B  are diagrams illustrating a first prediction method, and  FIG. 4  is a flowchart showing the process procedure of the first prediction method. In the first prediction method, as shown in  FIG. 3A , the correspondence relationship between the cathode condition and the beam characteristic is plotted. In the example in  FIG. 3A , when an electron beam is emitted from the electron gun  7  of the electron beam writing apparatus  2 , the value of the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons when the emission current is changed is plotted with the emission current that is the cathode condition on the horizontal axis and the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons that is the beam characteristic on the vertical axis. As shown in  FIG. 3A , the plots are generally disposed on a common straight line. That is, the amount of fluctuation of the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons to a variation in the emission current becomes substantially a constant value while the cathode  21  does not reach its life span. The above-described process of obtaining the amount of fluctuation is repeated at a plurality of times over a predetermined period (e.g., several months). 
     In  FIG. 3B , the horizontal axis represents time and the vertical axis represents the above-described amount of fluctuation, and the correspondence relationship between the time at which the amount of fluctuation in  FIG. 3A  is obtained and the amount of fluctuation is plotted.  FIG. 3B  shows a plurality of plots, and each plot indicates a value of the amount of fluctuation in each period in which the process in  FIG. 3A  is performed. 
     The above-described function generator  45  generates the function expressed by a polynomial, for example, by a fitting process, based on plots of  FIG. 3B . The fitting function may be generated by a past actual measurement value similarly to the first prediction method. Otherwise, the fitting function may be generated by a simulation. Here, a fitting parameter is generated by the fitting process and an extrapolation process. In the present embodiment, for example, a quadratic function may be preferably used as the fitting function. In the function in  FIG. 3B , the value of the amount of fluctuation on the vertical axis decreases with a lapse of time. This indicates that a variation in the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons to a variation in the emission current gradually decreases with time. The reason for such characteristics is that when the cathode  21  comes close to its life span, the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons passing through each aperture does not increase even though the emission current increases. 
     The prediction unit  44  determines that the time at which the function generated by the function generator  45  intersects with the threshold indicated by the broken line in  FIG. 3B  is the life span of the cathode  21 , and thus the replacement of the cathode  21  can be urged before this time is reached. 
     The threshold is set based on, for example, a result of performing a plurality of times of processing of obtaining a value of an amount of fluctuation of the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons to a variation in the emission current from the start of using the cathode  21  to the end of life span. Alternatively, a function may be generated by simulation, and the threshold may be determined from the curve shape of the function. 
     In  FIG. 3A , the values of the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons when the emission current is changed are plotted. However, the horizontal axis may indicate other cathode conditions such as a bias voltage instead of the emission current. In addition, the vertical axis may be another beam characteristic such as a beam size on the sample surface instead of the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons. 
       FIG. 4  is a flowchart showing a function generation procedure in the first prediction method. First, the emission current is changed at a certain time, and a value of the amount of fluctuation of the amount of transmitted electrons, the amount of reflected electrons, or the amount of secondary electrons to a variation in the emission current is obtained (Step S 1 ). As described above, it may take a period such as several months to obtain the amount of fluctuation in Step S 1 . Subsequently, the correspondence relationship between the time at which the process in Step S 1  is performed and the value of the amount of fluctuation is temporarily stored in a storage device (not shown) (Step S 2 ). 
     Subsequently, it is determined whether the processes in Steps S 1  and S 2  are repeated at M times (M is an integer of two or more) (Step S 3 ). The processes in Steps S 1  to S 3  are repeated until the number of repetitions reaches M times. That is, for example, the process of obtaining the amount of fluctuation is repeated M times over several months. When the number of times reaches M, the correspondence relationship between the time of M times stored in the storage device in Step S 2  and the value of the amount of fluctuation is plotted in a two-dimensional coordinate space in which the horizontal axis represents time and the vertical axis represents the value of the amount of fluctuation as shown in  FIG. 3B . 
     Subsequently, a fitting process and an extrapolation process are performed based on a plurality of plots, and a function as shown in  FIG. 3B  is generated (Step S 4 ). The process in Step S 4  is performed by the function generator  45 . Since the function generated in Step S 4  obtains the value of the amount of fluctuation using the time as a parameter and can be expressed by a predetermined formula or table, a predetermined formula or table representing the function is stored in the storage device in Step S 4 . 
     Subsequently, the life span of the cathode  21  is determined by the extrapolation process of the function generated in Step S 4  (Step S 5 ). The process in Step S 5  is performed by the prediction unit  44 . The broken line in  FIG. 3B  indicates the threshold, and the time at which the function intersects with the threshold represents the life span of the cathode  21 . The threshold may be determined in advance, or the threshold may be set according to the curve shape of the function. In practice, before the life span of the cathode  21  is reached, the life span of the cathode  21  is predicted from the newly measured plot position on the function to replace the cathode  21  before the life span is reached. 
     As described above, in the first prediction method, the magnitude of the amount of fluctuation of the beam characteristic to a variation in the cathode condition is obtained at each of the plurality of times, the function is generated from the obtained value, and the life span of the cathode  21  is predicted from the time at which the function intersects with the threshold. As a result, it is possible to accurately predict the replacement time of the cathode  21  before the cathode  21  actually reaches its life span in consideration of the cathode conditions and the beam characteristics. 
     Second Prediction Method 
       FIGS. 5A and 5B  are diagrams illustrating the second prediction method, and  FIG. 6  is a flowchart showing the process procedure of the second prediction method. In the second method, as shown in  FIG. 5A , the correspondence relationship between the cathode condition and the beam characteristic is plotted. In the example in  FIG. 5A , when an electron beam is emitted from the electron gun  7  of the electron beam writing apparatus  2 , the value of the detection current when the filament temperature is changed is plotted with the filament temperature that is the cathode condition on the horizontal axis and the detection current of the detector  46  that is the beam characteristic on the vertical axis, and the amount of fluctuation of the detection current when the filament temperature is changed is detected. 
     Similarly to the first prediction method, the cathode condition includes, for example, at least one of the emission current carried through the emitter  23 , the bias voltage applied to the filament  25 , the filament power supplied to the filament  25 , and the temperature of the filament  25 . In addition, the temporal change in the amount of fluctuation of the beam characteristic includes at least one of the amount of transmitted electrons of the aperture, the amount of the current of reflected electrons, the amount of the current of secondary electrons, and a variation in the bias voltage applied to the filament  25  of the cathode  21 . 
       FIG. 5B  plots the correspondence relationship between the time at which the amount of fluctuation in  FIG. 5A  is obtained and the amount of fluctuation with the horizontal axis representing time and the vertical axis representing the amount of fluctuation of the detection current described above.  FIG. 5B  shows a plurality of plots, and each plot indicates the amount of fluctuation of the detection current at the time at which the process in  FIG. 5A  is performed. 
     The function generator  45  generates a function expressed by the polynomial by a fitting process based on all the plots in  FIG. 5B . The fitting function is generated by the past actual measurement value similarly to the first prediction method. Otherwise, the fitting function may be generated by the simulation. Here, the fitting process and the extrapolation process are performed based on all the plots to generate the fitting parameter. In the function in  FIG. 5B , the amount of fluctuation on the vertical axis decreases with a lapse of time. This indicates that as the cathode  21  comes close to its life span, the detection current does not change much even though the filament temperature is changed, and the sensitivity decreases. Therefore, the time at which the function generated by the function generator  45  intersects with the threshold indicated by the broken line in  FIG. 5B  is determined as the life span of the cathode  21 , and thus the cathode  21  can be replaced at an appropriate time before the cathode  21  reaches its life span. As described above, in the second prediction method, the condition controller  43  changes the condition under which the electron beam is emitted from the cathode  21  in a plurality of ways. The prediction unit  44  predicts the life span of the cathode  21  based on a temporal change in the amount of fluctuation of the beam characteristic when the condition is changed in a certain range. More specifically, the function generator  45  generates a function that obtains a temporal change in the amount of fluctuation of the beam characteristic when the cathode condition is changed at each of the plurality of times. The prediction unit  44  determines that the life span of the cathode  21  is reached at the time at which a temporal change in the amount of fluctuation obtained by the function generated by the function generator  45  becomes a predetermined threshold. 
     The threshold in  FIG. 5B  is set based on the amount of fluctuation of the detection current of the cathode  21  that actually reaches the end of life span, similarly to the threshold in  FIG. 3B . Alternatively, a function may be generated by simulation, and the threshold may be determined from the curve shape of the function. 
       FIG. 6  is a flowchart showing a function generation procedure in the second prediction method. First, the filament temperature is changed at a certain time to obtain the amount of fluctuation of the detection current of the detector  46  (Step S 21 ). Subsequently, the correspondence relationship between the time at which the process in Step S 21  is performed and the detection current of the detector  46  is temporarily stored in the storage device (not shown) (Step S 22 ). 
     Subsequently, it is determined whether the processes in Steps S 21  and S 22  are repeated at N times (N is an integer of two or more) (Step S 23 ). The processes in Steps S 21  to S 23  are repeated until the number of repetitions reaches N times. When the number of times reaches N, the correspondence relationship between the time of N times stored in the storage device in Step S 22  and the value of the amount of fluctuation is plotted in a two-dimensional coordinate space in which the horizontal axis represents time and the vertical axis represents the amount of fluctuation value as shown in  FIG. 5B . 
     Subsequently, the fitting process and extrapolation process for a plurality of plots in the two-dimensional coordinate space are performed to generate a function as shown in  FIG. 5B  (Step S 24 ). Since the function generated in Step S 24  obtains the amount of fluctuation of the detection current using the time as a parameter and can be expressed by a predetermined formula or table, a predetermined formula or table corresponding to the function is stored in the storage device in Step S 24 . 
     Subsequently, the life span of the cathode  21  is determined based on the function generated in Step S 24  (Step S 25 ). The broken line in  FIG. 5B  indicates the threshold, and the time at which the function intersects with the threshold represents the life span of the cathode  21 . The threshold may be determined in advance, or the threshold may be set according to the curve shape of the function. In practice, before the life span of the cathode  21  is reached, the life span of the cathode  21  is predicted from the newly measured plot position on the function to replace the cathode  21  before the life span is reached. 
     As described above, in the second prediction method, the amount of fluctuation of the detection current of the detector  46  is obtained at each of the plurality of times, the function is generated from the obtained amount of fluctuation, and the replacement time of the cathode  21  is predicted from the time at which the function intersects with the threshold. As a result, it is possible to accurately predict the replacement time of the cathode  21  in consideration of the cathode conditions and the beam characteristics. 
     In both the first prediction method and the second prediction method described above, the life span of the cathode  21  is predicted based on a change in the beam characteristics when the cathode conditions are changed in a plurality of ways, and thus it is possible to accurately predict the life span of the cathode  21  before the cathode  21  reaches its life span. 
     While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosures. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosures. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosures.