Abstract:
An improved technique for inspecting photomasks employs simulated images of the resist pattern. A simulated image of an original pattern is compared to a simulated image generated from a pattern captured from a photomask manufactured from the original pattern. Alternatively, simulated images generated from captured data from two different instances of the same original pattern formed in a photomask are compared.

Description:
This application is a Continuation of U.S. Ser. No. 09/028,878, filed Feb. 24, 1998, now Pat. No. 6,091,845. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates in general to manufacturing semiconductor devices, and particularly to methods and apparatus for detecting defects introduced during the photolithography process. 
     BACKGROUND OF THE INVENTION 
     Defects in masks have always been a source of yield reduction in integrated circuit manufacture. As the minimum sizes approach 1 μm and below, and the circuits are designed with higher device densities, defects that were once tolerable can no longer be accepted. Common sources of defects are incorrect design of the mask patterns and flaws introduced into the patterns during the pattern generation process. Because each mask is printed on large numbers of wafers, fatal defects in a mask are highly undesirable. It would be useful if such defects could be detected and repaired prior to printing. 
     Device features are primarily fabricated using photolithography. The art of photolithography embodies techniques for creating two-dimensional patterns on a work surface by the controlled application of energy (such as electromagnetic, ion beam or other radiation) to a reactive material deposited on a wafer. In a photolithographic process the energy application is controlled through the use of a patterned photomask. The pattern is transferred to a photoresist coating on the wafer surface, forming a resist pattern. The wafer is then etched according to the resist pattern and, following the etch, subjected to further processing steps. The resulting features are the basis of the final circuit. As can be seen, the accuracy of the mask pattern and the resist pattern play important roles in the quality of the circuit. As area and feature size decreases, the impact of pattern defects and optical effects increases proportionately. Defects in either the mask or resist pattern during processing may have a direct affect on the accuracy and electronic characteristics of the semiconductor device. 
     Mask fabrication defects have a variety of causes. Such causes include, but are not limited to, defects in the original substrate, introduction of particulate matter during fabrication, scratches, or improper processing. In an attempt to minimize the number of defects introduced during wafer processing, photomasks are inspected after they are created and before they are used to pattern the wafers. Conventional inspection procedures examine several characteristics of the mask, including line width measurement, measurement of the pattern registration, whether all features present in the design database have been transferred to the mask, and whether any mask fabrication defects have been produced while manufacturing the mask. Current systems employ different inspection tools and methods for each of the above inspections. Originally, inspections were carried out by a human operator. As masks have become more complex this task has been relegated to automatic detection systems which perform the task more rapidly, with better sensitivity and repeatability and with fewer errors. 
     Some conventional inspection systems reduce material costs by comparing an image of the mask to the original data U.S. Pat. No. 5,481,624, issued to Kamon et al., entitled “Mask Inspecting Method and Mask Detector,” describes an inspection method similar to that disclosed in U.S. Pat. No. 4,641,353, issued to Kobayashi, entitled “Inspection Method and Apparatus for a Mask Pattern Used in Semiconductor Device Fabrication.” Kamon&#39;s method is directed to phase shifting masks, which include extra features in the mask to account for the unique optical effects of the phase shifting material used to manufacture the mask. Both Kobayashi and Kamon expose the actual pattern embedded in the mask using the same optical conditions as those used in a wafer exposure and compare that to the original pattern data These methods are an attempt to detect defects in the pattern before it is printed on wafers. 
     In a conventional die-to-database system such as that described in Kobayashi, the data defining the original pattern is compiled and prepared. A photomask is then fabricated using the original pattern data. The conventional inspection system acquires a two dimensional image from the photomask and conditions the resulting image. Conditioning the two-dimensional image cleans it up and enhances the image for future processing. The original pattern data is reformatted into a two-dimensional binary image acceptable to the inspection system. The reformatted data image is then converted to gray scale and filtered to resemble an acquired two-dimensional image. The two images are then aligned, and any discrepancies between the two images are flagged as potential defects. A conventional die-to-die inspection system works in a similar fashion. The primary difference is, instead of formatting one set of data from the original pattern data, mask data from two pattern images acquired from the mask are compared to each other. 
     Conventional inspection systems detect defects in any one of three images: that defined by the original data from which the mask is constructed; the pattern after it is printed on the mask; or the pattern after it has been printed on the wafer. In conventional systems, any inspection at a given stage of the process will potentially pick up anomalies introduced at that or earlier stages. However, using conventional inspection tools, many defects are not noticeable until the feature is produced in three dimensions by forming the pattern in the resist, due at least in part to the fact that defect printabilities the resist is a function of the exposure tool and of the resist characteristics. Defects which appear at this stage, however, are more costly to repair. When defects are discovered prior to resist processing, only a single mask need be repaired or replaced. Defects not discovered until after the resist is formed are likely not found until they have been replicated over large numbers of wafers. All of the affected wafers must then either be repaired or discarded. What is needed is a way to anticipate these less obvious defects before resist processing begins. 
     Existing inspection methods are limited because they are unable to anticipate the defects which appear when the resist is formed on the patterned wafer. Such defects result from defects in the pattern as well as from characteristic behavior of the expose tool or the resist material during processing. Existing methods do not take into account the characteristics of the expose tool or the resist material which will be formed according to the mask pattern. As a result, a mask may be inaccurately flagged as defective where, even though the mask pattern and original pattern are not identical, the “defect” would not impact the final resist pattern. Alternatively, there may be subtle mask defects that are not captured using conventional inspection techniques, but which cause resist defects due to the characteristics of the exposure tool and the resist material. The mask is, as a result, inaccurately flagged defect-free, when in fact one or more defects will appear when the resist is formed according to the pattern. What is needed is a way to accurately identify “true” defects at a point where they can be corrected or avoided at lower cost. 
     Systems which do not identify defects until after the pattern has been printed on the wafer increase process costs because each defect is likely repeated over a number of wafers before it is discovered. What is needed is a reliable way to determine, prior to forming the resist, whether resist formed according to a particular pattern will contain any defects. Such a system would reduce production costs. 
     SUMMARY OF THE INVENTION 
     The present invention eliminates the aforementioned drawbacks of the prior art. In contrast to conventional systems, the system of the present invention is a combination of image simulation procedures, providing extended defect detection capability to anticipate defects which would not otherwise be found until after the resist is formed. Conventional systems are limited in that they only compare mask images. A single correction in a mask pattern prior to printing and etching can prevent many defects since each mask pattern is printed on a number of wafers during the fabrication process. If the defect is not found until after resist formation, the number of integrated circuit devices which must be repaired and potentially thrown away increases dramatically. Many defects, however, do not appear until the three-dimensional feature is created during resist processing. 
     The present invention also provides a method of a mask inspection which uses available technology in a novel fashion to detect, before the resist is formed, defects which are likely to occur in the resist. In anticipating potential defects the system and method of the invention considers the effect of resist characteristics. 
     One embodiment of the present invention provides the ability to inspect defect printability instead of inspecting defects in the chrome. Because the printability of defects is amplified by resist processing, accounting for resist effects in the inspection process reduces the number of costly defects occurring during resist processing. 
     According to another embodiment the present invention provides an inspection system and method which can be used with both die-to-database and die-to-die inspections. 
     A method of inspecting a pattern on a mask is provided in another embodiment of the present invention In one implementation the mask pattern is manufactured from original pattern data, the mask comprising one or more copies of the pattern. The method comprises the steps of creating a first simulation of resist formed according to the original pattern data, capturing an inspection image of a portion of the mask, creating a second simulation of resist formed according to the inspection image, and comparing the first simulation to the second simulation. 
     According to another embodiment the first simulation is performed off-line. In one embodiment the pattern data is tree dimensional, while in another embodiment it is two-dimensional. In a further embodiment the inspection image comprises three-dimensional data, while in another embodiment it comprises two-dimensional data. According to another embodiment the simulations are three-dimensional. In a further embodiment the simulations are two-dimensional. 
     Yet another embodiment of the present invention describes a mask inspection system, wherein the mask has a plurality of identical patterns generated from a pattern. The mask inspection system also comprises an inspection device for capturing image data of a pattern in the mask, circuitry for using the captured image data to create an image of resist formed according to the pattern, circuitry for using the pattern data used to form the mask pattern to create a second image of resist formed, and circuitry for comparing the first image to the second image. 
     According to another embodiment of the present invention, a mask inspection system is provided, comprising a mask which comprises one or more patterns, including a first pattern and a second pattern, wherein the first pattern and the second pattern are generated from the same original pattern data. In addition, in this embodiment, the mask inspection system provides an inspection device for capturing image data of the one or more patterns, circuitry for creating an image of resist formed according to the first pattern using captured image data, circuitry for creating an image of resist formed according to the second pattern using captured image data, and circuitry for comparing the image of the first pattern to the image of the second pattern. 
     Yet another embodiment describes a computer program product which comprises a computer usable medium having a computer readable code means embodied therein for emulating an image. According to this embodiment the computer readable program code comprises means for causing a computer to read a first set of digitized image data, generate a first image from the first set of digitized data, read a second set of digitized image data, and generate a second image from the second set of digitized data. In a further embodiment, the computer readable program means comprises computer readable program means for incorporating resist characteristics in the generated images. 
     These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates a die-to-database inspection system according to one embodiment of the present invention. 
     FIG. 2 illustrates a die-to-de inspection system according to an alternative embodiment of the present invention. 
     FIG. 3 is a flow diagram illustrating the logic followed by the die-to database inspection system. 
     FIG. 4 is a flow diagram illustrating the logic followed by the die-to-die inspection system. 
     FIG. 5 is a pictorial representation of one embodiment of the method of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural, logical and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. 
     The method and apparatus of the present invention improves the sensitivity of mask inspection machines  100 . In one embodiment of the present invention, die-to-database inspection is provided as shown in FIG.  1 . Mask  161  has a plurality of identical mask patterns  160 . 1 - 160 . 8 , wherein mask patterns  160 . 1 - 160 . 8  are formed from the same pattern, as represented by pattern database  150 . 
     First, mask pattern  160 . 2  is exposed to energy source  110  and projected onto image sensor  130 . The mask image is then acquired using inspection machine  100 . The image acquisition process is well known in the art, and is incorporated in a variety of conventional inspection machines. These include a scanning electron microscope (SEM) inspection machines such as the KLA SEMSPEC™, an aerial image measurement system such as MSM- 100 ™ from Zeiss, Inc. or an optical inspection machine. One skilled in the art will recognnre that any image from any inspection tool can be used as input into the system of the invention. 
     Mask inspection machines  100  is not limited to any particular type of mask. In fact, the inspection machine is applicable to the following types of masks: a photomask, an ion projection mask, an e-beam projection mask, a x-ray projection mask, a x-ray mask, a mask with proximity effect correction, and a phase shifting mask Those skilled in the art will readily recognize that a wide variety of types of masks may be inspected using the present invention other than the ones listed here. 
     The image acquisition process generates simulated image  180 . According to one embodiment of the invention, this image may be a three-dimensional image, while in a second embodiment the image data acquired is two-dimensional. In the context of the present discussion “three-dimensional” means that, for every point of the image, the x position, y position, and visual properties (such as intensity) are identified. In the same manner, “two dimensional” means that, for every point of the image, only the x position, y position, and binary state of the point are recorded. 
     Where a three-dimensional image provides a complete representation of the image, a two-dimensional image provides what is essentially an outline of the image. One skilled in the art will recognize that a three-dimensional image comprises a significantly larger amount of data than a two-dimensional image. 
     As shown in FIG. 1, the resulting digitized image of  160 . 2 , whether two-or three-dimensional, is sent to image simulation circuitry, where it is used to construct image simulation  180 . In a similar manner, image data derived from original pattern data  150  is processed through image simulation circuitry, creating second simulated image  185 . 
     In one embodiment, image simulations  180  and  185  are three-dimensional. This embodiment provides a more complete and accurate rendition of the image, enhancing the benefits of the image comparison to be performed in following steps. In an alternate embodiment image simulation  180  and  185  are two-dimensional. The two-dimensional model provides a significant reduction in the amount of data that is processed by associated procedures and image simulation circuitry corresponding to image simulations  180  and  185 . 
     In one embodiment, image simulation circuitry corresponding to image simulations  180  and  185  comprises program logic which adds elevation data to the input image. According to one implementation of this embodiment, a first common elevation is applied to the masked areas. A second common elevation, lower relative to the first common elevation, is then applied to the unmasked areas. The difference between the two common elevations is the expected average width of the resist layer. The program logic then interpolates the edges of the areas at the first common elevation, emulating the sidewalls which will be formed between the two elevations. Algorithms which emulate the behavior of the resist material are incorporated into the program logic in order that the resulting interpolated sidewalls are a reasonable approximation of the feature sidewalls which will be formed when the device is manufactured. 
     The simulation performed by the present invention thus goes further than simply creating sidewalls based on a standard slope. The system of the present invention analyzes the masked areas in light of known resist characteristics, and modifies the resulting emulated features, including sidewalls, according to anticipated resist behavior. As a result of the described procedure, defects caused by anomalies in the mask or poorly designed features are represented as they are expected to appear on devices manufactured using the mask being inspected, and mask deficiencies can be identified and potentially costly resist defects avoided. 
     According to one embodiment, the simulation program logic is written in the C programming language and compiled into machine-executable code. Those skilled in the art will recognize, however, that other programming languages may be used without exceeding the scope and spirit of the present invention. Comrnercially available simulation software does not currently provide the functionality required to perform a three-dimensional analysis of masks. One software product which employs three-dimensional simulation is Prolith™. This product is, however, designed for a different type of analysis and is too slow and overly detailed, making it unacceptable for a mask inspection application. Other software products can simulate resist images from mask data, but they are not intended to be used to simulate resist images from insetion data Faim™, from Vector Technology, and Proxima™ and Proteus™, from Precim, are examples of existing software used for image simulations. 
     As previously discussed, image data derived from original pattern data  150  is processed through image simulation circuitry, creating a second simulated image  185 . The simulation process for each image incorporates logic which modifies the image data according to known characteristics of the resist used for forming a wafer. The two images  180  and  185  simulate the resist pattern; image  180  corresponding to original pattern data  150  and image  185  corresponding to mask image  160 . 2 . These images  180  and  185  are then forwarded to and compared by defect detection circuitry  140  for defects. 
     FIG. 2 illustrates a die-to-die inspection system according to an alternative embodiment of the present invention. A plurality of images are acquired through the same inspection machine  100  or another inspection machine connected to image simulation circuitry  180 . In this embodiment, instead of comparing acquired image  160 . 2  to the image derived from pattern database  150 , multiple acquired images are compared to each other. In this illustrative embodiment, acquired image  160 . 1  is compared to acquired image  160 . 2   
     The die-to-die mask inspection machine  100  thus comprises mask  161  having a plurality of identical patterns  160 . 1 - 160 . 8  wherein two or more wafer patterns are projected onto image sensor  130 . In FIG. 2, first pattern  160 . 1  and second pattern  160 . 2  are projected onto image sensor  130  wherein image simulation circuitry acquires image data of the two patterns. The acquired image data corresponding to each pattern is modified to characteristics of resist materials used for forming a wafer using mask  161 . After the image data is modified, image simulation  180  corresponding to first pattern  160 . 1  is formed and image simulation  182  corresponding to second pattern  160 . 2  is formed. Image simulations  180  and  182  are compared by defect detection  146  for defects. 
     Image simulation circuitry  180  is operationally independent from the other process modules  140 ,  150 . This allows a flexible implementation of the present invention. In one embodiment, simulation  185  of original data  150  is performed off-line. According to one embodiment this step is performed on a machine separate from but connected to the inpection machine  100 . In another embodiment it is performed on the inspection machine  100  prior to the actual inspection process. 
     Performing the simulation of the original data off-line increases efficiency by freeing up more resources for inspection processing. Generally the speed of an inspection system is directly related to the scanning speed of the mask. In one embodiment of the present invention, data processing is performed on the fly. As a result, simulating the resist image from the pattern acquired from the mask has limited impact on overall inspection time because it can be done in parallel to other inspection processing. 
     Inspection systems such as the KLA 351™ support parallel processing channels, enabling the addition of more computational power as necessary. The implementation of the system of the invention therefore provides extended pattern analysis without significantly increasing the overhead associated with mask inspection. 
     In one embodiment of the present invention, image simulation circuitry  180  is incorporated into inspection machine  100 . Alternatively, image simulation circuitry  180  is incorporated in a system physically separate from the inspection machine. Data and control information may be communicated via network or any type of removable media Those skilled in the art will recognize that a variety of configurations may be employed without exceeding the scope and spirit of the present invention. 
     FIG. 3 shows the logic followed by the image processor according to the die-to-database inspection system embodiment of the present invention. At the first process block  210 , the original pattern data describing the features to be fabricated is prepared. This step comprises the well-known process of quantifing the features of the mask in two dimensional space so that a mask representing those features may be fabricated. The next step of the process  220  is to manufacture a mask using the original pattern data. 
     Once the mask is created, inspection data is acquired at process block  230 . In one embodiment this step comprises taling an image from the mask and digitizing it using conventional mask inspection equipment. A simulation of the data is then created at process block  240 . In one embodiment, the simulation is three dimensional. In an alternate embodiment the simulation is two dimensional. One reason the two-dimensional embodiment may be employed is to reduce the amount of data that is required to perform the analysis. 
     A modified data set is created to retain the resulting digitized raw simulation data. At the next process block  250  the raw simulation data set is manipulated according to algorithms emulating particular characteristics of the exposure tool and resist material. A refined simulation of the modified image data is then created at process block  260 . The simulation steps employing the mask image data  240 ,  250 ,  260  are preferably performed in real time, as a large amount of data is collected and processed during the various steps. 
     In a separate process sequence, at process block  255  similar resist simulation algorithms are applied to the original pattern data set, creating a simulation of the modified original pattern data at process block  265 . This step may be performed on the inspection system. Alternatively, it may be performed offline prior to mask inspection, thereby reducing processing overhead when mask inspection is performed. 
     At process block  270  the two process flows are brought together and the image simulations are aligned and compared. In one embodiment of the present invention the image simulation steps  260  and  265  are performed by commercially available software packages, and image simulation comparison is performed by conventional inspection devices. 
     FIG. 4 shows the logic followed by the image processor according to the die-to-die inspection system embodiment of the present invention. At the first process block  210 , the original pattern data describing the features to be fabricated is prepared. The next step of the process  220  is to manufacture a mask having a plurality of identical patterns formed by the original pattern data. 
     Once the mask is created, inspection data is acquired at process block  230  and  232 , where process block  230  corresponds to a first pattern on the mask and process block  232  corresponds to a second pattern on the mask. In one embodiment this step comprises taking the images from the mask and digitizing them using conventional mask inspection equipment. Simulations of the data are then created at process blocks  240  and  242 . In one embodiment, the simulation is three dimensional. In an alternate embodiment the simulation is two-dimensional. 
     A modified data set is created to retain the resulting digitized raw simulation data. At the next process blocks  250  and  252 , the raw simulation data sets are manipulated according to algorithms emulating particular characteristics of the exposure tool and resist material. Refined simulations of the modified image data is then created at process block  260  and  262  for the first and second patterns. The simulation steps employing the mask image data  240  and  242 ,  250  and  252 ,  260  and  262  are preferably performed in real time, as a large amount of data is collected and processed during the various steps. 
     At process block  270  the two process flows are brought together and the image simulations are aligned and compared for defects. Incorporating multiple simulations of the mask images provides more accurate analysis of the mask features. The alignment process  270  includes logic to deal with any run-time bias between the images being aligned. 
     FIG. 5 is a pictorial representation of one embodiment of the method of the present invention. First the original pattern is designed and described by a set of digital data  310 . This set of original data is processed through simulation software  315 . In the embodiment illustrated, during this process the original two-dimensional pattern is convoluted to create a three-dimensional simulation of resist behavior  320  (shown in both perspective and top view). The original data  310  is also used to manufacture a mask  330 . 
     According to the example shown, a defect  332  is introduced during mask manufacture. Mask  330  is then inspected on image capture system  335 , which digitizes the mask image. Program logic incorporated in image simulation circuitry  180  converts the digitized mask image to a three-dimensional data image  340  (show in both a perspective view  341  and top view  342 ). Note the subtle anomaly  332  caused by a mask defect in mask  330 . 
     An erosion algorithm is included in the program logic for emulating the effect of mask defects on feature formation. One such algorithm is pixel erosion, which is a well-known image processing technique. Those skilled in the art will recognize that other erosion algorithms may be used without exceeding the scope of the present invention. 
     The program logic then creates a three-dimensional simulation of resist behavior  350  (show in both perspective view  351  and top view  352 ) from the digitized image  340 . Note that by modifying the inspection image  340  according to resist characteristics  345  anomaly  332  is now a very visible defect  332 . When the two resist simulations  320 ,  350  are compared  360  the defect  332  is easily detected. Those skilled in the art will recognize that this example is meant to be illustrative and not limiting in any way, and that other embodiments are possible. 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.