Patent Description:
Semiconductor fabrication typically requires fabricating multiple layers on a structure in which some or all of the layers include patterned features. Overlay metrology is the measurement of the relative positions of structures on various layers of a sample, which are critical to the performance of a fabricated device and must typically be controlled within tight tolerances. For example, overlay metrology may measure the relative positions of features on different sample layers as a measure of the layer-by-layer alignment of fabrication tools.

Not all device feature layouts are amenable to direct overlay measurements. Further, overlay measurements may damage or otherwise affect the performance of device features. Accordingly, overlay measurements are commonly performed on dedicated overlay targets having features designed for sensitive overlay measurements rather than directly on device features. However, differences in size, orientation, density, and/or location on the sample of overlay targets relative to the device features may introduce a mismatch between measured overlay at the target and actual overlay of device features. For example, features on different layers of overlay targets are commonly spatially separated to avoid overlap and facilitate measurements of features on buried layers. However, open areas associated with spatially separated features may not be compatible with microelectronics fabrication. Further, device features commonly include stacked structures such that overlay measurements of spatially separated features may introduce measurement errors.

<CIT> discloses a method of determining an overlay error during manufacturing of a multilayer semiconductor device.

<CIT> describes an overlay alignment measurement mark.

<CIT> discloses an overlay metrology mark.

Accordingly, ensuring device-relevant overlay measurements on overlay targets remains an ongoing challenge in overlay metrology.

An overlay metrology system as recited in claim <NUM> is disclosed.

An overlay metrology method as recited in claim <NUM> is disclosed.

The present disclosure has been particularly shown and described with respect to certain embodiments and specific features thereof. The embodiments set forth herein are taken to be illustrative rather than limiting. It should be readily apparent to those of ordinary skill in the art that various changes and modifications in form and detail may be made without departing from the spirit and scope of the disclosure.

Embodiments of the present disclosure are directed to systems and methods for measuring device-correlated overlay using overlay targets with stacked device-scale features based on a combination of intra-layer and inter-layer measurements. For example, an overlay target may include stacked device-scale features on multiple layers such that a device-relevant overlay measurement may be based on the relative positions of the device-scale features. However, direct measurement of the relative positions of stacked device-scale features may be impractical or undesirable.

It is recognized herein that a semiconductor device may by formed as multiple printed layers of patterned material on a substrate. Each printed layer may be fabricated through a series of process steps such as, but not limited to, one or more material deposition steps, one or more lithography steps, or one or more etching steps. Further, each printed layer must be fabricated within specific tolerances to properly construct the final device. For example, printing characteristics such as, but not limited to, the linewidths, sidewall angles, and relative placement of printed elements in each layer must be well characterized and controlled. Accordingly, metrology targets may be fabricated on one or more printed layers to enable efficient characterization of the fabrication process. In this regard, deviations of printed characteristics of metrology targets on a printed layer may be representative of deviations of printed characteristics of all printed elements on the layer including device features forming a portion of the semiconductor device.

It is recognized herein that various overlay metrology tools may be used to measure overlay. For example, optical metrology tools (e.g., light-based metrology tools using electromagnetic radiation for illumination and/or detection) may provide high-throughput overlay measurements using numerous techniques such as, but not limited to, determining relative positions of spatially-separated features on multiple layers in an image, directly measuring pattern placement errors (PPE) on multiple layers, or scatterometry in which overlay is determined based on light scattered and/or diffracted from diffraction gratings on multiple layers. For the purposes of the present disclosure, the term "optical metrology tools," "optical metrology techniques," and the like indicate metrology tools and techniques using electromagnetic radiation of any wavelength such as, but not limited to, x-ray wavelengths, extreme ultraviolet (EUV) wavelengths, vacuum ultraviolet (VUV) wavelengths, deep ultraviolet (DUV) wavelengths, ultraviolet (UV) wavelengths, visible wavelengths, or infrared (IR) wavelengths. However, resolution limits of optical metrology tools typically require feature sizes larger than device-scale features, which may introduce a systematic error between the optical metrology measurement and the actual overlay on device features of interest, depending on the wavelengths of an illumination source. By way of another example, particle-based metrology tools such as, but not limited to, a scanning electron microscope (SEM) metrology tool (e.g., a critical dimension SEM (CD-SEM), or the like), or a focused ion beam (FIB) metrology tool may resolve device-scale features. Further, particle-beam metrology tools may have a limited ability to simultaneously measure features on multiple sample layers based on the particle penetration depth. For example, low-energy particle beams may be used to characterize a top layer (e.g., a current layer), while relatively higher-energy particle beams may penetrate deeper into the sample to characterize features on previously-fabricated layers. However, many particle-based metrology tools may have relatively lower throughput than optical metrology tools and may potentially induce damage to one or more layers during measurement. Systems and methods for overlay measurement are generally described in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and PCT Application No. <CIT>.

Embodiments of the present disclosure are directed to systems and methods for measuring device-correlated overlay using intra-layer measurements of device-scale features and reference features coupled with inter-layer overlay measurements of the reference features. Layers of an overlay target may thus include device-scale features suitable for intra-layer measurements as well as reference features suitable for both intra-layer and inter-layer measurements. Further, embodiments of the present disclosure are directed to overlay targets suitable for measuring overlay of any number of sample layers (e.g., two or more sample layers).

A device-correlated overlay (OVLdevice) may thus be, but is not required to be, represented as: <MAT> where OVLref is an inter-layer overlay measurement of reference features and PPE is a pattern placement error (PPE) associated with a difference between intra-layer pattern placement distances separating device-scale features and reference features in each layer of interest. For example, a device-correlated overlay measurement between a first layer and a second layer may be determined based on a measurement of a distance D<NUM> between a selected device-scale feature and a selected reference features on the first layer after the fabrication of the first layer, a measurement of a distance D<NUM> between a selected device-scale feature and a selected reference features on the second layer after the fabrication of the second layer, and a through-target overlay measurement OVLref of reference features on the first and second layers. Accordingly, the device-relevant overlay may be expressed as: <MAT>.

The reference features may have any dimensions and may be designed for any type of overlay measurement known in the art such as, but not limited to, optical overlay measurements, particle-based overlay measurements, or PPE measurements. In this regard, the reference features may have different dimensions than the device-scale features to facilitate inter-layer overlay measurements. For example, reference features suitable for optical measurement may have dimensions selected to be greater than the optical resolution of a selected optical metrology tool.

By way of another example, reference features suitable for particle-based measurement may have dimensions selected to be greater than a resolution of a selected particle-based metrology tool at each layer. It is recognized herein that the resolution of a particle-based metrology system may be higher for surface-level features than for sub-surface features located on sub-surface layers due to particle-sample interactions such as, but not limited to particle scattering in the material. Accordingly, it may be the case that a particle-based metrology system may accurately resolve device-scale features on a surface layer, but may not accurately resolve (e.g., within selected tolerances) device-scale features on a sub-surface layer, particularly if the sub-surface features are stacked below the surface-level features. In this regard, the dimensions of the reference features on any layer may be selected to be resolvable by the metrology system within identified tolerances.

The pattern placement error PPE may be influenced by multiple factors. For example, as described previously herein, the placement of features within an exposure field of a lithography tool may be influenced by the size, shape, density, and/or orientation of the features. Accordingly, any differences between the reference features and the device-scale features on a given layer may result in pattern placement errors. By way of another example, intra-field fabrication errors may be induced by aberrations in a lithography tool during an exposure step such as, but not limited to, lens aberrations or turbulence caused by heat in the lithography tool.

It is to be understood that equation (<NUM>) above expressing overlay between two sample layers and the associated description is provided only for illustrative purposes and should not be interpreted as limiting. As described previously herein, device-correlated overlays may be generated for any number of sample layers. For example, the device correlated overlays of equations (<NUM>) and/or (<NUM>) may represent overlay between any two layers of a multi-layer overlay target. In this regard, through-target overlay measurements of reference features (OVLref) and PPE measurements may be generated for any number of sample layers to provide multi-layer device-correlated overlay measurements.

Additional embodiments of the present disclosure are directed to metrology targets with multiple patterns of device-scale features and one or more common reference features. In this regard, a common reference overlay measurement (OVLref) may be used to determine device-relevant overlay for each of the multiple patterns of device-scale features, which may facilitate high-throughput overlay measurements.

Additional embodiments of the present disclosure are directed to an overlay target including repeated sets of reference features. For example, an overlay target may include periodically distributed reference features located in multiple layers. In this regard, the reference overlay (OVLref) may be determined based on multiple measurements of the repeating features. Further, repeating features may facilitate reduced energy deposited per area on the overlay target and thus reduced potential for damage during the overlay measurement.

Further embodiments of the present disclosure are directed to generating device-relevant overlay correctables based on the device-relevant overlay measurements. The overlay correctables may then be provided to fabrication tools (e.g., lithography tools) as feedback and/or feedforward data. For example, overlay measurements associated with a current process step measured on a sample may be used to compensate for drifts and maintain overlay within selected tolerances for the process step on subsequent samples in the same or subsequent lots. By way of another example, overlay measurements associated with a current process step may be fed-forward to adjust subsequent process steps to compensate for any measured overlay errors.

<FIG> is a conceptual view of an overlay metrology system <NUM> suitable for device-correlated metrology measurements, in accordance with one or more embodiments of the present disclosure. In one embodiment, the overlay metrology system <NUM> include at least one overlay metrology tool <NUM> suitable for measuring intra-layer pattern placement distances as well as inter-layer overlay measurements of stacked overlay target features.

In another embodiment, the overlay metrology system <NUM> includes a controller <NUM>. In another embodiment, the controller <NUM> includes one or more processors <NUM> configured to execute program instructions maintained on a memory medium <NUM>. In this regard, the one or more processors <NUM> of controller <NUM> may execute any of the various process steps described throughout the present disclosure. For example, the controller <NUM> may receive data from the overlay metrology tool <NUM> and may further generate device-correlated overlay data. By way of another example, the controller <NUM> may generate device-relevant overlay correctables based on data from the overlay metrology tool <NUM>.

Further, the controller <NUM> may be communicatively coupled to one or more external fabrication tools such as, but not limited to, a lithography tool. In this regard, the controller <NUM> may operate as an advanced process controller (APC) suitable for controlling the inputs of the external fabrication tools to maintain overlay within selected overlay tolerances.

The one or more processors <NUM> of a controller <NUM> may include any processing element known in the art. In this sense, the one or more processors <NUM> may include any microprocessor-type device configured to execute algorithms and/or instructions. In one embodiment, the one or more processors <NUM> may consist of a desktop computer, mainframe computer system, workstation, image computer, parallel processor, or any other computer system (e.g., networked computer) configured to execute a program configured to operate the overlay metrology system <NUM>, as described throughout the present disclosure. It is further recognized that the term "processor" may be broadly defined to encompass any device having one or more processing elements, which execute program instructions from a non-transitory memory medium <NUM>. Further, the steps described throughout the present disclosure may be carried out by a single controller <NUM> or, alternatively, multiple controllers. Additionally, the controller <NUM> may include one or more controllers housed in a common housing or within multiple housings. In this way, any controller or combination of controllers may be separately packaged as a module suitable for integration into overlay metrology system <NUM>.

The memory medium <NUM> may include any storage medium known in the art suitable for storing program instructions executable by the associated one or more processors <NUM>. For example, the memory medium <NUM> may include a non-transitory memory medium. By way of another example, the memory medium <NUM> may include, but is not limited to, a read-only memory (ROM), a random-access memory (RAM), a magnetic or optical memory device (e.g., disk), a magnetic tape, a solid-state drive, and the like. It is further noted that memory medium <NUM> may be housed in a common controller housing with the one or more processors <NUM>. In one embodiment, the memory medium <NUM> may be located remotely with respect to the physical location of the one or more processors <NUM> and controller <NUM>. For instance, the one or more processors <NUM> of controller <NUM> may access a remote memory (e.g., server), accessible through a network (e.g., internet, intranet, and the like). Therefore, the above description should not be interpreted as a limitation on the present invention but merely an illustration.

The overlay metrology tool <NUM> may include any type of metrology tool known in the art suitable for characterizing intra-layer pattern placement distances and/or inter-layer overlay measurements. For example, the overlay metrology tool <NUM> may illuminate a sample with an illumination beam and may further collect radiation emanating from the sample in response to the illumination beam. The illumination beam may include any type of illumination beam suitable for probing a sample such as, but not limited to, a light beam (e.g., photons), an electron beam, or an ion beam. Further, the radiation emanating from the sample may include photons, electrons, ions, neutral particles, or the like. Accordingly, the overlay metrology tool <NUM> may include an optical metrology tool, an e-beam metrology tool, an ion-beam metrology tool, or the like.

The overlay metrology tool <NUM> may further operate in either an imaging mode or a non-imaging mode. For example, the overlay metrology tool <NUM> operating in an imaging mode may illuminate a portion of the sample larger than the system resolution and capture one or more images of the illuminated portion of the sample on a detector. The captured image may be any type of image known in the art such as, but not limited to, a brightfield image, a darkfield image, a phase-contrast image, or the like. Further, captured images may be stitched together (e.g., by the controller <NUM>, or the like) to form a composite image of the sample. By way of another example, the overlay metrology tool <NUM> may generate multiple images of the sample using multiple detectors either simultaneously or sequentially. For instance, the overlay metrology tool <NUM> may generate images of the sample from different perspectives. In another instance, the overlay metrology tool <NUM> may generate images of the sample using different beam energies (e.g., particle beam energies, optical intensities, wavelengths, or the like). By way of another example, the overlay metrology tool <NUM> may scan a focused beam across the sample and capture radiation and/or particles emanating from the sample on one or more detectors at one or more measurement angles to generate the image. The focused beam may be scanned across the sample by modifying the beam path and/or by translating the sample through a focal volume of the focused beam. For instance, particle beams may be scanned using controlled electromagnetic fields (e.g., generated using one or more beam deflectors, or the like). In another instance, light beams may be scanned using scanning mirrors (e.g., galvo mirrors, piezo-electric mirrors, or the like).

Referring now to <FIG> and <FIG>, various embodiments of an overlay metrology tool <NUM> are described. For example, the overlay metrology tool <NUM> may include, but is not required to include, a particle-based overlay metrology tool 102a and/or an optical overlay metrology tool 102b.

<FIG> is a conceptual view of a particle-based overlay metrology tool 102a, in accordance with one or more embodiments of the present disclosure. The particle-based overlay metrology tool 102a may include any type of metrology tool suitable for resolving device features or device-scale features such as, but not limited to an electron-beam metrology tool (e.g., a SEM, a CD-SEM, or the like), or an ion-beam metrology tool (e.g., a focused-ion-beam (FIB) metrology tool.

In one embodiment, the particle-based overlay metrology tool 102a a particle source <NUM> (e.g., an electron beam source, an ion beam source, or the like) to generate a particle beam <NUM> (e.g., an electron beam, a particle beam, or the like). The particle source <NUM> may include any particle source known in the art suitable for generating a particle beam <NUM>. For example, the particle source <NUM> may include, but is not limited to, an electron gun or an ion gun. In another embodiment, the particle source <NUM> is configured to provide a particle beam with a tunable energy. For example, particle source <NUM> including an electron source may, but is not limited to, provide an accelerating voltage in the range of <NUM> kV to <NUM> kV. As another example, a particle source <NUM> including an ion source may, but is not required to, provide an ion beam with an energy in the range of <NUM> to <NUM> keV.

In another embodiment, the particle-based overlay metrology tool 102a includes one or more particle focusing elements <NUM>. For example, the one or more particle focusing elements <NUM> may include, but are not limited to, a single particle focusing element or one or more particle focusing elements forming a compound system. In another embodiment, the one or more particle focusing elements <NUM> include a particle objective lens <NUM> configured to direct the particle beam <NUM> to a sample <NUM> located on a sample stage <NUM>. Further, the one or more particle source <NUM> may include any type of electron lenses known in the art including, but not limited to, electrostatic, magnetic, uni-potential, or double-potential lenses.

In another embodiment, the particle-based overlay metrology tool 102a includes at least one particle detector <NUM> to image or otherwise detect particles emanating from the sample <NUM>. In one embodiment, the particle detector <NUM> includes an electron collector (e.g., a secondary electron collector, a backscattered electron detector, or the like). In another embodiment, the particle detector <NUM> includes a photon detector (e.g., a photodetector, an x-ray detector, a scintillating element coupled to photomultiplier tube (PMT) detector, or the like) for detecting electrons and/or photons from the sample surface.

It is to be understood that the description of a particle-based overlay metrology tool 102a as depicted in <FIG> and the associated descriptions above are provided solely for illustrative purposes and should not be interpreted as limiting. For example, the particle-based overlay metrology tool 102a may include a multi-beam and/or a multi-column system suitable for simultaneously interrogating a sample <NUM>. In a further embodiment, the particle-based overlay metrology tool 102a may include one or more components (e.g., one or more electrodes) configured to apply one or more voltages to one or more locations of the sample <NUM>. In this regard, the particle-based overlay metrology tool 102a may generate voltage contrast imaging data.

It is recognized herein that the penetration depth of the particle beam <NUM> in the sample <NUM> may depend on the particle energy such that higher-energy beams typically penetrate deeper into the sample. In one embodiment, the particle-based overlay metrology tool 102a utilizes different particle energies to interrogate different layers of the device based on the penetration depth of the particle beam <NUM> into the sample <NUM>. For example, the particle-based overlay metrology tool 102a may utilize a relatively low-energy electron beam (e.g., approximately <NUM> keV or less) and may utilize a higher energy beam (e.g., approximately <NUM> keV or higher) to characterize a previously fabricated layer. It is recognized herein that the penetration depth as a function of particle energy may vary for different materials such that the selection of the particle energy for a particular layer may vary for different materials.

<FIG> is a conceptual view of an optical overlay metrology tool 102b, in accordance with one or more embodiments of the present disclosure. The optical overlay metrology tool 102b may include any type of optical overlay metrology tool known in the art suitable for generating overlay data associated with two or more layers of a sample.

In one embodiment, the optical overlay metrology tool 102b includes an optical illumination source <NUM> to generate an optical illumination beam <NUM>. The optical illumination beam <NUM> may include one or more selected wavelengths of light including, but not limited to, ultraviolet (UV) light, visible light, or infrared (IR) light.

The optical illumination source <NUM> may be any type of illumination source known in the art suitable for generating an optical illumination beam <NUM>.

The optical illumination source <NUM> may include any type of illumination source suitable for providing an optical illumination beam <NUM>. In one embodiment, the optical illumination source <NUM> is a laser source. For example, the optical illumination source <NUM> may include, but is not limited to, one or more narrowband laser sources, a broadband laser source, a supercontinuum laser source, a white light laser source, or the like. In this regard, the optical illumination source <NUM> may provide an optical illumination beam <NUM> having high coherence (e.g., high spatial coherence and/or temporal coherence). In another embodiment, the optical illumination source <NUM> includes a laser-sustained plasma (LSP) source. For example, the optical illumination source <NUM> may include, but is not limited to, a LSP lamp, a LSP bulb, or a LSP chamber suitable for containing one or more elements that, when excited by a laser source into a plasma state, may emit broadband illumination. In another embodiment, the optical illumination source <NUM> includes a lamp source. For example, the optical illumination source <NUM> may include, but is not limited to, an arc lamp, a discharge lamp, an electrode-less lamp, or the like. In this regard, the optical illumination source <NUM> may provide an optical illumination beam <NUM> having low coherence (e.g., low spatial coherence and/or temporal coherence).

In another embodiment, the optical illumination source <NUM> directs the optical illumination beam <NUM> to a sample <NUM> via an illumination pathway <NUM>. The illumination pathway <NUM> may include one or more illumination pathway lenses <NUM> or additional optical components <NUM> suitable for modifying and/or conditioning the optical illumination beam <NUM>. For example, the one or more optical components <NUM> may include, but are not limited to, one or more polarizers, one or more filters, one or more beam splitters, one or more diffusers, one or more homogenizers, one or more apodizers, or one or more beam shapers. The illumination pathway <NUM> may further include an objective lens <NUM> configured to direct the optical illumination beam <NUM> to the sample <NUM>.

In another embodiment, the sample <NUM> is disposed on a sample stage <NUM>. The sample stage <NUM> may include any device suitable for positioning and/or scanning the sample <NUM> within the optical overlay metrology tool 102b. For example, the sample stage <NUM> may include any combination of linear translation stages, rotational stages, tip/tilt stages, or the like.

In another embodiment, the optical overlay metrology tool 102b includes a detector <NUM> configured to capture light emanating from the sample <NUM> through a collection pathway <NUM>. The collection pathway <NUM> may include, but is not limited to, one or more collection pathway lenses <NUM> for collecting light from the sample <NUM>. For example, a detector <NUM> may receive light reflected or scattered (e.g., via specular reflection, diffuse reflection, and the like) from the sample <NUM> via one or more collection pathway lenses <NUM>. By way of another example, a detector <NUM> may receive light generated by the sample <NUM> (e.g., luminescence associated with absorption of the optical illumination beam <NUM>, or the like). By way of another example, a detector <NUM> may receive one or more diffracted orders of light from the sample <NUM> (e.g., <NUM>-order diffraction, ±<NUM> order diffraction, ±<NUM> order diffraction, and the like).

The detector <NUM> may include any type of detector known in the art suitable for measuring illumination received from the sample <NUM>. For example, a detector <NUM> may include, but is not limited to, a CCD detector, a TDI detector, a photomultiplier tube (PMT), an avalanche photodiode (APD), or the like. In another embodiment, a detector <NUM> may include a spectroscopic detector suitable for identifying wavelengths of light emanating from the sample <NUM>.

The collection pathway <NUM> may further include any number of optical elements to direct and/or modify collected illumination from the sample <NUM> including, but not limited to one or more collection pathway lenses <NUM>, one or more filters, one or more polarizers, or one or more beam blocks.

In one embodiment, the detector <NUM> is positioned approximately normal to the surface of the sample <NUM>. In another embodiment, the optical overlay metrology tool 102b includes a beamsplitter <NUM> oriented such that the objective lens <NUM> may simultaneously direct the optical illumination beam <NUM> to the sample <NUM> and collect light emanating from the sample <NUM>. Further, the illumination pathway <NUM> and the collection pathway <NUM> may share one or more additional elements (e.g., objective lens <NUM>, apertures, filters, or the like).

The optical overlay metrology tool 102b may measure overlay based on any technique known in the art such as, but not limited to, imaged-based techniques or scatterometry-based techniques. Further, the optical overlay metrology tool 102b may measure overlay based on features on any layer of the sample <NUM> by having the optical illumination beam <NUM> propagate through a surface layer to interact with features on one or more previously fabricated layers.

In another embodiment, the overlay metrology tool <NUM> includes an edge-placement metrology tool suitable for measurements of the pattern placement distances (or pattern placement errors) of various features on a sample layer. For example, the position of the sample stage <NUM> may be tightly monitored to provide accurate positioning results over a large field of view. Further, it is recognized herein that positioning accuracy based on monitoring actual positions of the sample stage <NUM>, as opposed to positioning accuracy based solely on control of the sample stage <NUM> itself, may be limited only by the monitoring accuracy. In one instance, though not shown, the position of the sample stage <NUM> along one or more directions is monitored using an interferometer, which may provide, but is not required to provide, nanometer or sub-nanometer accuracy. Further, the overlay metrology tool <NUM> including an edge-placement metrology tool may be based on any type of imaging technology such as, but not limited to, optical or particle-beam imaging. The measurement of the positions and dimensions of structures using edge-placement metrology is generally described in Int'l <CIT>, and <CIT>.

In another embodiment, the overlay metrology system <NUM> includes multiple overlay metrology tools <NUM>. For example, the overlay metrology system <NUM> may include a first overlay metrology tool <NUM> suitable for measuring intra-layer pattern placement distances of device-scale features and a second overlay metrology system <NUM> suitable for measuring inter-layer overlay. Further, the multiple overlay metrology tools <NUM> may have different operational principles. For example, an overlay metrology tool <NUM> suitable for measuring intra-layer pattern placement distances of device-scale features may include a particle-based metrology tool having sufficient resolution to resolve device-scale features. By way of another example, an overlay metrology tool <NUM> suitable for measuring inter-layer overlay may include either a particle-based metrology tool or an optical metrology tool.

<FIG> includes a top view <NUM> of a device-correlated overlay target <NUM>, in accordance with one or more embodiments of the present disclosure. <FIG> includes a profile view <NUM> of a device-correlated overlay target <NUM>, in accordance with one or more embodiments of the present disclosure. In one embodiment, the device-correlated overlay target <NUM> includes features on multiple layers of the sample <NUM>. For example, as illustrated in the profile view <NUM>, the device-correlated overlay target <NUM> may include features on a first layer <NUM> and a second layer <NUM> fabricated on top of and subsequent to the first layer <NUM>.

In another embodiment, the device-correlated overlay target <NUM> includes both device-scale features and reference features on each layer of interest. For example, the device-correlated overlay target <NUM> may include first-layer pattern of device-scale features 210a and a second-layer pattern of device-scale features 210b. Similarly, the device-correlated overlay target <NUM> may include a first-layer pattern of reference features 212a and a second-layer pattern of reference features 212b.

In another embodiment, the device-correlated overlay target <NUM> includes stacked (e.g., overlapping) patterns. For example, as illustrated in the profile view <NUM>, the second-layer pattern of device-scale features 210b may be stacked on the first-layer pattern of device-scale features 210a such that a device-correlated overlay <NUM> may correspond to a relative displacement of the second-layer pattern of device-scale features 210b with respect to the first-layer pattern of device-scale features 210a. By way of another example, the second-layer pattern of reference features 212b may be stacked on the first-layer pattern of reference features 212a such that a reference overlay <NUM> may correspond to a relative displacement of the second-layer pattern of reference features 212b with respect to the first-layer pattern of reference features 212a.

In one embodiment, the first layer <NUM> and the second layer <NUM> include the same feature patterns. For example, the first-layer pattern of device-scale features 210a may be substantially the same as the second-layer pattern of device-scale features 210b across the device-correlated overlay target <NUM>. Similarly, the first-layer pattern of reference features 212a may be substantially the same as the second-layer pattern of reference features 212b across the device-correlated overlay target <NUM>. In another embodiment, the first layer <NUM> and the second layer <NUM> include different feature patterns. For example, features on the second layer <NUM> may be fabricated with a different period than features on the first layer <NUM>. In one instance, as illustrated by the top view <NUM>, features in the second layer <NUM> (e.g., the second-layer pattern of device-scale features 210b and the second-layer pattern of reference features 212b) may be fabricated with twice the period of features on the first layer <NUM> (e.g., the first-layer pattern of device-scale features 210a and the first-layer pattern of reference features 212a). In this regard, the features on the first layer may be alternately visible or covered in the top view <NUM>. By way of another example, the first-layer pattern of device-scale features 210a and the second-layer pattern of device-scale features 210b may be fabricated with different characteristics such as, but not limited to, feature dimensions, (e.g., critical dimensions, lengths, widths, and/or heights), sidewall angles, or orientations.

In another embodiment, device-scale features are fabricated at a nominal selected distance (e.g., pattern placement distance) from the reference features. However, as described previously herein, intra-field errors can lead to variations in the relative placement of the device-scale features and the reference features. For example, as illustrated in the profile view <NUM> a first-layer pattern placement distance <NUM> associated with a separation between selected portions of the first-layer pattern of device-scale features 210a and the first-layer pattern of reference features 212a may differ from a second-layer pattern placement distance <NUM> associated with a separation between selected portions of the second-layer pattern of device-scale features 210b and the second-layer pattern of reference features 212b.

Accordingly, as described in equation <NUM>, the device-correlated overlay <NUM> (OVLdevice) may be characterized in terms of the reference overlay <NUM> (OVLref) and the PPE associated with a difference between the first-layer pattern placement distance <NUM> and the second-layer pattern placement distance <NUM>.

The pattern placement distances (e.g., the first-layer pattern placement distance <NUM> and the second-layer pattern placement distance <NUM>) may be determined using any technique known in the art. For example, the pattern placement distances may be determined by analyzing (e.g., with the controller <NUM>) an image of at least a portion of the device-correlated overlay target <NUM> generated with a particle-based metrology tool (e.g., particle-based overlay metrology tool 102a) with a resolution sufficient to resolve the device-scale features.

Further, the reference overlay <NUM> (OVLref) may be determined using any technique known in the art. For example, the reference overlay <NUM> may be determined by analyzing (e.g., with the controller <NUM>) an image of at least a portion of the device-correlated overlay target <NUM> generated with a particle-based metrology tool (e.g., particle-based overlay metrology tool 102a) with a resolution sufficient to resolve the reference features. By way of another example, the reference overlay <NUM> may be determined using an optical metrology tool (e.g., optical overlay metrology tool 102b). For instance, the controller <NUM> may analyze an optical image of the reference features on multiple layers of interest. In another instance, the controller <NUM> may determine the reference overlay <NUM> using a model-based analysis of a diffraction pattern associated with interaction of an optical illumination beam <NUM> with both the first-layer pattern of reference features 212a and the second-layer pattern of reference features 212b.

In another embodiment, a pattern of reference features (e.g., the first-layer pattern of reference features 212a and the second-layer pattern of reference features 212b) may be periodically distributed along a scan direction. The repeated reference features may provide multiple measurement points for the reference overlay <NUM> along the scan direction, which may reduce stochastic measurement noise compared to a single measurement and thus increase the measurement accuracy. Conversely, repeated reference features may reduce a dose on the sample during an overlay measurement (e.g., associated with a particle beam <NUM>, an optical illumination beam <NUM>, or the like) required to generate an overlay measurement of a selected precision. Further, reducing the dose required for an overlay measurement may mitigate charging effects as well as resist shrinkage effects, which may further increase the measurement precision.

<FIG> is a top view <NUM> of periodically-distributed reference features of an overlay target (e.g., device-correlated overlay target <NUM>, or the like) suitable for scanning measurements, in accordance with one or more embodiments of the present disclosure. In one embodiment, periodically distributed first-layer features <NUM> are located on a first layer of a sample (e.g., sample <NUM>) along a scanning direction <NUM>. In another embodiment, periodically-distributed second-layer features <NUM> are located on a second layer of the sample along the scanning direction <NUM>. Further, as illustrated in <FIG>, the second-layer features <NUM> may be stacked on the first-layer features <NUM> such that a swath <NUM> of an imaging beam (e.g., a particle beam <NUM>, an optical illumination beam <NUM>, or the like) may simultaneously image both the first-layer features <NUM> and the second-layer features <NUM>.

The reference features may have dimensions selected to be greater than a resolution of a selected overlay metrology tool (e.g., the particle-based overlay metrology tool 102a, the optical overlay metrology tool 102b, or the like) such that the features may be resolved by the overlay metrology tool. For example, a length <NUM> of first-layer features <NUM> along the scanning direction <NUM>, a length <NUM> of second-layer features <NUM> along the scanning direction <NUM>, and/or the pitch <NUM> along the scanning direction <NUM> may be selected such that the first-layer features <NUM> and the second-layer features <NUM> are resolvable with the selected overlay metrology tool.

The reference features on any layer may be further segmented. For example, the reference features on all layers of the overlay target may be periodically distributed with a resolvable pitch <NUM> and reference features on any layer of the target may be further segmented with a device-scale pitch <NUM> to provide process-compatibility with design rules of the layer and minimize systematic placement errors between the reference features and device features on the layer. As described previously herein, the resolution of a particle-based overlay metrology tool 102a may be lower for sub-surface features (e.g., first-layer features <NUM>) relative to surface-level features (e.g., second-layer features <NUM>) such that the segments separated with the device-scale pitch <NUM> may not be resolvable with the overlay metrology tool. However, so long as the pitch <NUM>, the length <NUM> of the first-layer features <NUM>, and the length <NUM> of the second-layer features <NUM> are resolvable, the reference overlay <NUM> may be measured.

The device-correlated overlay target <NUM> may be further configured to facilitate overlay measurements in multiple directions. For example, the profile view <NUM> illustrates the determination of overlay along the X-direction. In one embodiment, as illustrated by the top view <NUM>, the device-correlated overlay target <NUM> includes a first set of features <NUM> oriented along the X-direction suitable for overlay measurements along the X-direction and a second set of features <NUM> oriented along the Y-direction suitable for overlay measurements along the Y-direction.

A device-correlated overlay target may additionally include multiple sets of different device-scale feature patterns and/or multiple sets of different reference feature patterns. For the purposes of the present disclosure, such an overlay target is referred to as a composite overlay target. It is recognized herein that a fabricated layer may include device features (e.g., forming part of a semiconductor device) with varying dimensions, densities, and/or orientations. Accordingly, the varying dimensions, densities and/or orientations of the device features may lead to varying pattern placement error and thus varying on-device overlay. In one embodiment, a composite device-correlated overlay target may include different device-scale feature patterns to correspond to different device structures on a given layer. In this regard, device-correlated overlay may be measured for each type of device-scale feature pattern to facilitate robust and accurate overlay measurements for multiple device structures.

Similarly, a composite device-correlated overlay target may include multiple sets of reference feature patterns. In this regard, overlay may be measured based on any selected combination of device-scale feature patterns and reference feature patterns.

<FIG> is a conceptual view of a composite device-correlated overlay target <NUM>, in accordance with one or more embodiments of the present disclosure. In one embodiment, the composite device-correlated overlay target <NUM> includes multiple device-scale patterns 302a-g. In another embodiment, the composite device-correlated overlay target <NUM> includes multiple reference patterns 304a,b. The multiple device-scale patterns 302a-g as well as the multiple reference patterns 304a,b may be distributed in any spatially-separated orientation. For example, as illustrated in <FIG>, the composite device-correlated overlay target <NUM> may be divided into a grid such in which each segment of the grid includes a device-scale pattern and/or a reference pattern.

In one embodiment, a device-correlated overlay measurement may be generated between any device-scale patterns 302a-g and any reference patterns 304a,b. In this regard, a selected device-scale patterns 302a-g and a selected reference patterns 304a,b may be considered in combination as a device-correlated overlay target (e.g., similar to the device-correlated overlay target <NUM> illustrated in <FIG>, but not limited to the specific design illustrated in <FIG>). Accordingly, a device-correlated overlay measurement may be generated based on equation <NUM> and the illustrative description of the device-correlated overlay target <NUM> of <FIG>.

Further, the device-scale patterns 302a-g and the reference patterns 304a,b may include features oriented along any direction. For example, each device-scale patterns 302a-g or the reference patterns 304a,b may include features distributed along multiple directions suitable for the determination of overlay along the multiple directions. By way of another example, device-scale patterns 302a-g or the reference patterns 304a,b may include features distributed along a single direction.

It is recognized herein that a composite device-correlated overlay target (e.g., composite device-correlated overlay target <NUM>) may facilitate efficient measurement of device-correlated overlay values for multiple device-scale patterns. For example, a single reference overlay measurement (e.g., OVLref) associated with any of reference patterns 304a,b may be applied to determine multiple device-relevant overlays of multiple device patterns.

Further, device-correlated overlay measured with different combinations of device-scale patterns and reference patterns may facilitate the determination of systematic fabrication errors such as, but not limited to, aberrations of the lithography system.

It is to be understood that the composite device-correlated overlay target <NUM> illustrated in <FIG> is provided solely for illustrative purposes and should not be interpreted as limiting. For example, a composite device-correlated overlay target <NUM> may have any shape suitable for including multiple device-scale feature patterns and/or reference feature patterns such as, but not limited to, a rectangle or a circle.

<FIG> is a flow diagram illustrating steps performed in a method <NUM> for measuring device-correlated overlay, in accordance with one or more embodiments of the present disclosure. Applicant notes that the embodiments and enabling technologies described previously herein in the context of the overlay metrology system <NUM> should be interpreted to extend to method <NUM>. It is further noted, however, that the method <NUM> is not limited to the architecture of the overlay metrology system <NUM>.

In one embodiment, the method <NUM> includes a step <NUM> of fabricating a first layer of an overlay target on a sample including at least a pattern of device-scale features and a pattern of reference features. For example, an overlay target may include device-scale features that have one or more characteristics (e.g., size, shape, density, orientation, or the like) similar to device features forming a portion of a semiconductor device on the first layer. In this regard, the device-scale features may print with similar characteristics as the device features. The overlay target may additionally include reference features having selected characteristics (e.g., size, shape, density, orientation, or the like) suitable for providing inter-layer overlay measurements with corresponding features in subsequent layers. Further, the characteristics of the reference features that may differ, but are not required to differ, from the characteristics of the device-scale features.

In another embodiment, the method <NUM> includes a step <NUM> of measuring, with an imaging system subsequent to fabricating the first layer, a first-layer pattern placement distance between the pattern of device-scale features and the pattern of reference features on the first layer. The first-layer pattern placement distance may be measured using any technique known in the art. For example, the step <NUM> may include generating one or more images of the device-scale features and the reference features on the first layer and determining the first-layer pattern placement distance based on the one or more images.

In one embodiment, the imaging system used in step <NUM> is a particle-based imaging system (e.g., particle-based overlay metrology tool 102a, or the like) suitable for resolving the device-scale features.

In another embodiment, the method <NUM> includes a step <NUM> of fabricating a second layer of the overlay target on the sample including at least the pattern of device features and the pattern of reference features. For example, the pattern of device-scale features and the pattern of reference features may be duplicated on the second layer. In one embodiment, the device-scale features on the first and second layers are stacked (e.g., overlapped). In this regard, a device-correlated overlay may be associated with a relative displacement of the device-scale features on the second layer with respect to the first layer. Similarly, the pattern of reference features on the first and second layers may be stacked such that a reference overlay may be associated with a relative displacement of the reference features on the second layer with respect to the first layer.

In another embodiment, the method <NUM> includes a step <NUM> of measuring, with the imaging system subsequent to fabricating the second layer, a second-layer pattern placement distance between the pattern of device features and the pattern of reference features on the second layer. For example, the step <NUM> may be substantially similar to the step <NUM> repeated on the second layer. In one embodiment, first-layer pattern placement distance and the second-layer pattern placement distance may be measured using the same imaging system to provide consistent measurements.

In another embodiment, the method <NUM> includes a step <NUM> of measuring, with an overlay metrology system, a reference overlay based on relative positions of the pattern of reference features on the first layer and the pattern of reference features on the second layer.

The reference overlay may be measured using any overlay technique known in the art. For example, the reference overlay may be measured using a particle-based overlay tool (e.g., particle-based overlay metrology tool 102a, or the like). In this regard, the particle-based overlay metrology tool may utilize different particle energies to interrogate different layers of the device based on the penetration depth of a particle beam into the sample. For example, the particle-based overlay metrology tool may utilize a relatively low-energy electron beam (e.g., approximately <NUM> keV or less) and may utilize a higher energy beam (e.g., approximately <NUM> keV or higher) to characterize a previously fabricated layer. Further, the penetration depth as a function of particle energy may vary for different materials such that the selection of the particle energy for a particular layer may vary for different materials.

By way of another example, the reference overlay may be measured using optical metrology techniques such as, but not limited to, optical imaging metrology or scatterometry overlay metrology. In this regard, the reference features on the first and the second layers may be fabricated with dimensions greater than the optical resolution of the selected optical overlay metrology tool. As described previously herein, optical metrology techniques may utilize any wavelength of electromagnetic radiation such as, but not limited to, x-ray wavelengths, extreme ultraviolet (EUV) wavelengths, vacuum ultraviolet (VUV) wavelengths, deep ultraviolet (DUV) wavelengths, ultraviolet (UV) wavelengths, visible wavelengths, or infrared (IR) wavelengths.

In another embodiment, the reference features on the first layer and the second layer are periodically distributed along a scan direction. In this regard, the reference overlay may be measured along the scan direction and may provide multiple measurement points for the reference overlay, which may reduce stochastic measurement noise. Accordingly, the dose required to generate the reference overlay measurement may be decreased relative to non-repeating structures, which may mitigate errors associated with the measurement itself such as, but not limited to, charging effects and resist-layer shrinkage.

In accordance with the invention, the method <NUM> includes a step <NUM> of determining a device-relevant overlay for the pattern of device-scale features by adjusting the reference overlay with a difference between the first-layer pattern placement distance and the second-layer pattern placement distance. For example, as described previously herein with respect to equation <NUM>, a device-relevant overlay (OVLdevice) may be characterized in terms of the reference overlay (OVLref) associated with step <NUM> and the ΔPPE associated with a difference between the first-layer pattern placement distance of step <NUM> and the second-layer pattern placement distance of step <NUM>.

In another embodiment, the method <NUM> includes a step <NUM> of providing overlay correctables based on the device-relevant overlay to a lithography system to modify exposure conditions of at least one subsequent exposure.

For example, step <NUM> may include generating control parameters (or corrections to the control parameters) for fabrication tools such as, but not limited to, lithography tools based on the device-relevant overlay. The control parameters may be generated by a control system such as, but not limited to, the controller <NUM> of the overlay metrology system <NUM>. The overlay correctables may be provided as part of a feedback and/or a feedforward control loop. In one embodiment, the device-relevant overlay measurements associated with a current process step measured on a sample are used to compensate for drifts of one or more fabrication processes and may thus maintain overlay within selected tolerances across multiple exposures on subsequent samples in the same or different lots. In another embodiment, the device-relevant overlay measurements associated with a current process step may be fed-forward to adjust subsequent process steps to compensate for any measured overlay errors. For example, the exposure of patterns on subsequent layers may be adjusted to match the measured overlay of the subsequent layers.

The herein described subject matter sometimes illustrates different components contained within, or connected with, other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality. Likewise, any two components so associated can also be viewed as being "connected" or "coupled" to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being "couplable" to each other to achieve the desired functionality. Specific examples of couplable include but are not limited to physically interactable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interactable and/or logically interacting components.

Claim 1:
An overlay metrology system (<NUM>), comprising:
a controller (<NUM>) including one or more processors (<NUM>) configured to execute program instructions causing the one or more processors to:
measure (<NUM>) a first-layer pattern placement distance (<NUM>) between a pattern of device scale features (210a) and a pattern of reference features (212a) on a first layer (<NUM>) of an overlay target (<NUM>) on a sample (<NUM>);
measure (<NUM>), subsequent to fabricating a second layer (<NUM>) including at least the pattern of device scale features (210b) and the pattern of reference features (212b) a second-layer pattern placement distance (<NUM>) between the pattern of device scale features and the pattern of reference features on the second layer;
measure (<NUM>) a reference overlay (<NUM>) based on relative positions of the pattern of reference features on the first layer and the second layer, wherein dimensions of the pattern of reference features on the first layer are resolvable by an imaging system through the second layer;
determine (<NUM>) a device-relevant overlay for the pattern of device-scale features by adjusting the reference overlay with a difference between the first-layer pattern placement distance and the second-layer pattern placement distance; and
provide (<NUM>) overlay correctables based on the device-relevant overlay to a lithography system to modify exposure conditions of at least one subsequent exposure.