Patent Description:
In a manufacturing process of a semiconductor device, a photolithography technique is used in which a circuit pattern formed on a transfer mask is transferred onto a semiconductor substrate (semiconductor wafer) through a reduction projection optical system with irradiation of exposure light onto the mask. At present, a mainstream wavelength of the exposure light is <NUM> for argon fluoride (ArF) excimer laser light. A pattern having a size smaller than the exposure wavelength can be formed finally by adopting a process called multi-patterning combining multiple exposure processes and multiple processing (etching) processes.

However, since it is necessary to form still finer patterns, EUV lithography using, as exposure light, extreme ultraviolet (hereinafter referred to "EUV") light having a wavelength shorter than ArF excimer laser light is promising. EUV light is light having a wavelength of from about <NUM> to <NUM>, such as specifically, light having a wavelength of about <NUM>. This EUV light has a very low transmissivity in substances and cannot be utilized for a conventional transmissive projection optical system or mask, thus, a reflection-type optical elemental device is applied. Therefore, a reflective mask is also proposed as a mask for the pattern transfer. A reflective mask has a multilayer reflection film that is formed on a substrate and reflects EUV light, and a patterned absorber film that is formed on the multilayer reflection film and absorbs EUV light. On the other hand, the material before patterning the absorber film is called a reflective mask blank, and is used for a material of the reflective mask.

In a manufacturing process of a reflective mask, a pattern is formed by etching the absorber film of the reflective mask blank, and then the pattern is usually inspected. When a defect is detected, the defect is repaired. However, in the case of reflective masks so-called phase defects, at which reflectance decreases due to disorder of the structure in the multilayer reflection film, may exist in addition to defects derived from the absorber film and the absorber pattern in some cases. Furthermore, it is very difficult to directly correct a phase defect in the multilayer reflection film after forming the absorber pattern.

Under these circumstances, many studies have been made on a technique for detecting a phase defect in a reflective mask blank. For example, <CIT> (Patent Document <NUM>) discloses a technique utilizing a dark field inspection image as a method of detecting a phase defect inside a multilayer reflection film using EUV light. Further, <CIT> (Patent Document <NUM>) discloses a technique utilizing a bright field in X-ray microscopy as a method of detecting a phase defect inside a multilayer reflection film using EUV light. These methods accurately detect a phase defect in a multilayer reflection film. In particular, in the dark field detection method using EUV light described in Patent Document <NUM>, a phase defect that is unique in a reflective mask blank having a multilayer reflection film can be detected as a bright spot signal with high sensitivity. Therefore, this is a very effective method for determining whether a phase defect is present or not after forming a multilayer reflection film.

On the other hand, as a method for finally accomplishing reduced phase defects at the stage of manufacturing the reflective mask, even if phase defects remain in the reflective mask blank, for example <CIT> (Patent Document <NUM>) discloses a technique of improving the projection image when transferring a pattern by an exposure tool by modifying the contour of the absorber pattern, when the absorber pattern is formed from the absorber film of the reflective mask blank in which the phase defect exists, without repairing the phase defect. In this method, after forming the absorber pattern, it is necessary to accurately obtain the position of the phase defect in the multilayer reflection film on the basis of coordinates of the absorber pattern. However, it is hard to pinpoint the position of a phase defect after the pattern has been formed.

Further, <CIT> (Patent Document <NUM>) discloses a technique of patterning an absorber film while avoiding the position of a phase defect, by forming a reference mark on the absorber film, obtaining the position of the phase defect in the multilayer reflection film as the position of a corresponding convexo-concave of the surface of the absorber film on the multilayer reflection film, converting to positional information of the defect with respect to the reference mark, and further modifying drawing data for patterning the absorber film in accordance with the positional information of the defect. In this method, it is not necessary to engrave the reference mark into the multilayer reflection film, therefore, risk of particle generation caused by engraving the reference mark can be reduced. However with some phase defects, disorder of the structure in the multilayer reflection film that reduces reflectance scarcely appears as a convexo-concave formation of the surface of the multilayer reflection film. Thus, in the inspection of the absorber film, it is hard to obtain the positional information of all phase defects with accuracy. Therefore, a reflective mask blank obtained by this method cannot reliably be drawn so as to form the absorber pattern avoiding all concerned phase defects, thus, the method cannot avoid phase defects with high accuracy when forming the absorber pattern.

Furthermore, <CIT> (Patent Document <NUM>) discloses a method of fabricating a reflective mask and <CIT> (Patent Document <NUM>) discloses a defect position correction method for a reflective mask.

As a method for detecting and avoiding phase defects with high accuracy, for example, it is considered that a concave or convex mark is provided on a substrate for utilizing as a reference mark when configuring the coordinate system. According to the method, it is possible to form the multilayer reflection film on the reference mark formed on the substrate and to determine the position of a phase defect in the multilayer reflection film with reference to the reference mark in the subsequent inspection of the phase defect. Further, when the absorber film is formed on the multilayer reflection film on the reference mark, and the drawing position of a pattern for forming the absorber pattern is determined in accordance with the position of the phase defect in the multilayer reflection film determined with reference to the reference mark, it is possible to form the absorber pattern so as to avoid the phase defect by utilizing the same reference mark.

However, when the layers constituting the multilayer reflection film are laminated over the reference mark, and further the absorber film is laminated thereon, the total thickness of the film stack usually exceeds <NUM>. In the case that the reference mark is deeply buried by the films, it cannot be expected to achieve high accuracy in determination of position. It would be possible to engrave the reference mark in the multilayer reflection film, after forming the multilayer reflection film and before forming the absorber film. However the multilayer reflection film and absorber film are preferably formed continuously. In particular, if the reference mark is formed in the multilayer reflection film at this stage by engraving, the risk of particle defects is increased in the resulting reflective mask blank.

The present invention has been made to address the above problems. A first aspect of the present invention is to provide, with respect to a defect such as a phase defect which influences a reflective mask manufactured from a reflective mask blank and a method of manufacturing a reflective mask blank that enables an accurate grasp of the position of a defect in a multilayer reflection film, particularly even a finer defect, after forming the multilayer reflection film on a substrate and also after forming an absorber film on the multilayer reflection film. A further aspect is to provide a method of manufacturing a reflective mask blank that enables efficient formation of an absorber pattern, mitigating influence of a defect in the multilayer reflection film by avoiding the defect with high accuracy. A further aspect of the present invention is to provide a method of manufacturing a reflective mask that enables efficient formation of an absorber pattern from such a reflective mask blank while mitigating influence of the defect in the multilayer reflection film, avoiding the defect with high accuracy.

In order to solve the above-mentioned problems, the inventors have found that, with respect to a reflective mask blank including a substrate, and a multilayer reflection film for EUV light reflection, a protection film, and an absorber film for EUV light absorption formed on one main surface of the substrate, and a conductive film formed on another main surface of the substrate, when a coordinate reference mark is formed on the other main surface side, particularly on the conductive film, the coordinate reference mark is not buried by the films formed on the one main surface side of the substrate, and the position of a defect such as a phase defect in the multilayer reflection film can still be determined with high accuracy.

Further, the inventors have found that a reflective mask blank in which a coordinate reference mark is formed on the other main surface side can be manufactured by inspecting a defect in a multilayer reflection film and an absorber film once at the stage in which the multilayer reflection film and absorber film have been formed; obtaining positional information of the detected defect on the basis of coordinates defined with reference to the coordinate reference mark and saving the positional information into a recording medium; then, forming the absorber film, inspecting a defect in the absorber film, obtaining positional information of the detected defect on the basis of coordinates defined with reference to the coordinate reference mark and saving the positional information into a recording medium. According to the method, a position of a defect can be accurately determined and held in accordance with the information stored in a recording medium. Further, a reflective mask can be obtained from a reflective mask blank by forming efficiently an absorber pattern in such a way as to mitigate an influence of the defect in the multilayer reflection film, in accordance with the positional information of the defect stored in the recording medium, thereby avoiding the effect of a defect such as a phase defect with high accuracy.

In one aspect, the invention provides a method of manufacturing a reflective mask blank, the mask blank comprising a substrate,a multilayer reflection film for EUV light reflection, a protection film, and an absorber film for EUV light absorption formed on one main surface of the substrate, in that order from the substrate side, and a conductive film formed on the other main surface of the substrate,the method comprising the steps of:.

Preferably, in step (A2), the coordinate reference mark is formed on the conductive film formed in the step (A1).

Preferably, when defects are detected in step (B2), step (B2) includes steps of creating a processing sequence for the defects, and saving the processing sequence into the recording medium along with the positional information. Typically, the processing sequence is a priority for processing the defects, the priority being determined on the basis of a printability of the detected defects.

In a further aspect the invention provides a method of manufacturing a reflective mask, comprising preparing a reflective mask blank by a method as described above and forming an absorber pattern by etching and removing part of the absorber film of the reflective mask blank.

According to the invention, with respect to a defect such as a phase defect which has influences on a reflective mask manufactured from a reflective mask blank, the position of the defect in the multilayer reflection film, particularly even a finer defect, can be accurately grasped after forming the multilayer reflection film on a substrate, further after forming an absorber film on the multilayer reflection film. Further, a reflective mask blank can be manufactured by forming efficiently an absorber pattern that can mitigate influence of the defect in the multilayer reflection film with avoiding the defect in high accuracy.

A reflective mask blank according to the invention includes a substrate, and a multilayer reflection film for EUV light reflection, a protection film (for the multilayer reflection film), and an absorber film for EUV light absorption formed on one main surface (front side) of the substrate in this order from the substrate side, and a conductive film formed on another main surface (back side) of the substrate which is the opposite side to the one main surface. The conductive film is formed to hold a reflective mask electrostatically on a mask stage of an exposure tool. The conductive film has a thickness of normally <NUM> to <NUM>. In the above description, one main surface of the substrate is defined as the front side or the upper side, and another main surface is defined the back side or the lower side. However, the terms front and back sides or the upper and lower sides in both surfaces are only for the sake of convenience. Two main surfaces (film forming surfaces) are referred to as "one" and "other" main surfaces, respectively. The front and back sides or the upper and lower sides can be substituted. Meanwhile, a reflective mask is formed by patterning the absorber film of the reflective mask blank to form an absorption pattern (a pattern of the absorber film).

<FIG> illustrate an example of a reflective mask for EUV exposure as a typical reflective mask. <FIG> is a plane view of an outline from the side of that surface of the reflective mask on which an absorber pattern is formed, and <FIG> is an enlarged cross-sectional view of a device pattern area of the reflective mask in <FIG>. As shown in <FIG>, a device pattern region MDA constituting a circuit pattern of a semiconductor integrated circuit device is formed on the predetermined position located at the central portion of one main surface side of a substrate <NUM> of a reflective mask RM. Alignment mark areas MA1, MA2, MA3, MA4, that include marks for alignment of the reflective mask or wafer alignment marks, are formed in a peripheral portion outside the device pattern region MDA. Further, a multilayer reflection film <NUM> for EUV light reflection, a protection film <NUM>, and an absorber pattern <NUM> for EUV light absorption are formed on one main surface of the substrate <NUM> in this order from the side of the substrate <NUM>, and a conductive film <NUM> is formed on the other main surface of the substrate <NUM>.

It is preferable to use a substrate composed of a low thermal expansion material and having a sufficiently flattened surface. For example, the substrate has a thermal expansion coefficient preferably within ±<NUM>×<NUM>-<NUM>/°C, more preferably within ±<NUM>×<NUM>-<NUM>/°C. The main surface of the substrate has a surface roughness (RMS value) of preferably not more than <NUM>, more preferably not more than <NUM>. Particularly, this surface roughness may be satisfied at least at a region on which an absorber pattern is formed (for example, the device pattern region MDA in <FIG>) in the main surface on which an absorber film is formed, preferably at the whole of the main surface on which an absorber film is formed. Such a surface roughness can be obtained by polishing the substrate.

The multilayer reflection film is a multilayer film consisting of layers composed of a material having a low refraction index and layers composed of a material having a high refraction index laminated alternately. For EUV light having exposure wavelength of <NUM> to <NUM> (normally, wavelength of about <NUM>), for example, an Mo/Si laminated film that includes layers of molybdenum (Mo) as the material having a lower refraction index, and layers of silicon (Si) as the material having a higher refraction index laminated alternately, e.g. for about <NUM> cycles (<NUM> layers of each), may be used. A thickness of the multilayer reflection film is normally about <NUM> to <NUM>.

The protection film is called a capping layer and is provided to protect the multilayer reflection film when the absorber pattern disposed on the protection film is formed or the absorber pattern is corrected. As a material of the protection film, for example, silicon (Si), ruthenium (Ru), or a ruthenium (Ru) compound added with niobium (Nb) and/or zirconium (Zr) may be used. A thickness of the protection film is normally about <NUM> to <NUM>.

The absorber pattern is a mask pattern that absorbs EUV light and is formed by patterning the absorber film. As a material of the absorber film, for example, a compound containing tantalum (Ta) as a main component, or a compound containing chromium (Cr) as a main component may is used. The absorber film may consist of a single layer or multiple layers. A thickness of the absorber film is normally about <NUM> to <NUM>.

The reflective mask blank may have a hard mask film on the absorber film for assisting the patterning of the absorber film. This hard mask film is usually removed after the absorber pattern is formed and is not left in the reflective mask. Further, a resist film (photoresist film) that is used for patterning the absorber film may be formed in the reflective mask blank.

A defect, specifically a so-called a phase defect at which the reflectance decreases due to disorder of the structure in the multilayer reflection film, exists in some cases of a reflective mask. Hereafter, a phase defect generated in the multilayer reflection film is described. <FIG> are drawings to explain a phase defect in a reflective mask for EUV light exposure. <FIG> is a cross-sectional view to explain a state of a phase defect existing in a multilayer reflection film before forming an absorber film, <FIG> is a cross-sectional view to explain a state of the phase defect exposed on the multilayer reflection film, and <FIG> is a cross-sectional view to explain a state of the phase defect covered with an absorber pattern.

<FIG> illustrates a state in which a convex phase defect <NUM> is formed extending through the multilayer reflection film <NUM> and the protection film <NUM> that are formed on the defect when the multilayer reflection film <NUM> is formed on the surface of the substrate <NUM>, as a result of the multilayer reflection film <NUM> being formed on the main surface of the substrate on which a fine or small convex portion is locally present. The numeral symbol <NUM> represents a conductive film. Although <FIG> illustrates the case that a fine convex portion is present on the main surface of the substrate <NUM>, also when a fine concave portion is present on the main surface of the substrate <NUM>, a concave phase defect <NUM> will be formed. Even if a fine convex or concave portion is present on the main surface of the substrate <NUM>, when the convex shape or the concave shape is gently flattened by the smoothing effect in the process of forming respective layers of the multilayer reflection film <NUM>, a convex or concave shape may scarcely appear on the finally obtained surface of the multilayer reflection film <NUM> or protection film <NUM> in some cases. However, even in such a case, if a fine convex or concave shape portion is present in the multilayer reflection film <NUM>, the portion still acts as a phase defect that generates a certain phase shift to reflected light and reduces reflectance.

When a reflective mask blank is manufactured by forming the absorber film on the protection film <NUM> in a state in which a phase defect <NUM> is present as shown in <FIG>, and then, forming the absorber pattern by patterning the absorber film, if the exposed phase defect <NUM> is present between adjacent absorber pattern portions <NUM>, as shown in <FIG>, and the height of the convex portion or the depth of the concave portion is, for example, at least about <NUM> to <NUM>, phase of the reflected light is disturbed and reflectance is decreased, and thus, a defect appears in a pattern projection image. On the other hand, when the phase defect <NUM> is covered by an absorber pattern portion <NUM>, and the reflectance of the phase defect <NUM> portion is sufficiently low, a defect does not appear in the projection image of the pattern of the reflective mask. Accordingly, when manufacturing a reflective mask, a defect in a pattern projection image caused by a phase defect can be avoided when a circuit pattern is formed for which the portion at which the phase defect is present is to be covered by the absorber pattern. For this purpose, it is important that the position (coordinates) of the phase defect existing in the reflective mask blank can be accurately determined. Further, it is important that the position (coordinates) of the phase defect can be accurately grasped when the absorber film is patterned, and that the determined position corresponds to the coordinates of the drawing pattern for forming the absorber pattern.

In the reflective mask blank, a coordinate reference mark is formed on the other main surface side (back side) of the substrate, which is the opposite side to the one main surface side (front side) on which the multilayer reflection film, protection film and absorber film are formed. The coordinate reference mark is a reference (coordinate reference) on a two-dimensional coordinate or in a three-dimensional coordinate system for determining the position of a specific location, such as a location at which a defect exists in a reflective mask blank or a reflective mask obtained from the reflective mask blank. Thus, a coordinate reference mark is formed normally at at least two positions, preferably at least three positions, more preferably at least four positions. A coordinate reference mark may have a convex shape. However, a concave shape is convenient and preferable for engraving onto a substrate or a film to form the mark. Particularly, in the case that the other main surface side is an attracted surface for application of an electrostatic chuck, the coordinate reference mark is more preferably formed to a concave shape.

A planar/plan shape of the coordinate reference mark is not particularly limited as long as its position can be detected by the inspection light of an optical inspection tool. A cross-form mark 106a as shown in <FIG>, a lengthwise lines mark 106b consisting of a plurality of spaced lines (six lines in this case) pattern as shown in <FIG>, and a crosswise lines mark 106C consisting of a plurality of spaced lines (six lines in this case) pattern as shown in <FIG> are exemplified. Dimensions of the mark are not particularly limited. For example, the width may be <NUM> to <NUM>, and the length may be <NUM> to <NUM>.

In the reflective mask blank, the coordinate reference mark is formed preferably on a conductive film, when present. Normally, a conductive film is formed on the other main surface side of the substrate so that an electrostatic chuck can be applied to the reflective mask when the reflective mask obtained from the reflective mask blank is loaded on an exposure tool. Or, a coordinate reference mark may be formed directly on the substrate. However, it is advantageous to form the coordinate reference mark by processing the conductive film in view of processability of the coordinate reference mark. In addition, when the reflective mask is loaded on the exposure tool, even if the coordinate reference mark is formed on the conductive film, the function of the conductive film is not impaired. It is an advantage of forming the coordinate reference mark on the conductive film. A concave coordinate reference mark is normally formed on the conductive film by engraving a part of the conductive film, particularly a part of the outer periphery of the conductive film. Generally, the coordinate reference mark is not used for loading the reflective mask on the exposure tool.

<FIG> is a bottom view of a reflective mask blank in which coordinate reference marks are formed on a conductive film. In this case, the conductive film <NUM> is formed on the other main surface side of the substrate <NUM>, and four concave coordinate reference marks <NUM> that are formed by engraving are formed within respective regions or portions in the outer periphery of the conductive film <NUM> (particularly, within each of four mark-formation areas <NUM> near the four corners, in this case).

The coordinate reference mark formed on the side opposing to the side which will be formed a circuit pattern is utilized as a common reference for a reference of position for inspection of defects such as phase defects existing in a multilayer reflection film, a reference of position for drawing an absorber pattern, a reference of position for defect inspection, and other references without laminating layers for forming the circuit pattern such as a multilayer reflection film, a protection film, an absorber film, and other films onto the coordinate reference mark. In addition, since a thick film is not laminated on the coordinate reference mark so as to deeply bury the coordinate reference mark in the films, high accuracy can be obtained in determining the position. Further, unlike a method of forming the absorber film after forming the coordinate reference mark on the multilayer reflection film or protection film, the coordinate reference mark is formed on the side opposite to the side on which a circuit pattern will be formed. Thus, it is not needed to conduct a processing of the coordinate reference mark that has a risk of generating particles after the multilayer reflection film or protection film is formed.

Next, a method for manufacturing the reflective mask blank will be described. In the invention, the reflective mask blank is suitably manufactured by a method including the respective steps of:.

This method is concretely described with reference to the drawings. <FIG> are diagrams to explain each step of manufacturing the reflective mask blank of the invention. <FIG> is a cross-sectional view of a substrate. <FIG> is a cross-sectional view of a state where a conductive film is formed on the other main surface of the substrate. <FIG> is a cross-sectional view of a state where coordinate reference marks are formed on the conductive film. <FIG> is a cross-sectional view of a state where a multilayer reflection film and a protection film are formed on one main surface of the substrate in the order. <FIG> is a cross-sectional view of a state where an absorber film is formed on the protection film.

In step (A1), a substrate <NUM> is prepared as shown in <FIG>. As the substrate <NUM>, a substrate having one main surface and an other main surface, that have a predetermined surface roughness, is prepared. Next, as shown in <FIG>, a conductive film <NUM> is formed on the other main surface of the substrate <NUM>.

In step (A2), coordinate reference marks are formed on the other main surface side. In the case shown in <FIG>, the coordinate reference marks are formed at predetermined positions in the outer periphery of the conductive film <NUM>. The coordinate reference mark can be formed by etching and removing a part of the conductive film <NUM>. As a shape of the coordinate reference mark, the same shapes of alignment marks or fiducial marks commonly used in reflective masks may be applied. Preferably there are plural marks, as described above. Particularly, it is necessary to keep the one main surface of the substrate clean after forming the conductive film and the coordinate reference mark. Thus, the substrate may be cleaned after forming the conductive film or the coordinate reference mark, if required. Even if the one main surface of the substrate has been contaminated while forming the coordinate reference mark, the surface of the substrate itself is easy to be cleaned up by cleaning process. So, steps (A1) and (A2) are preferably conducted before step (B1).

In step (B1), a multilayer reflection film <NUM> and a protection film <NUM> are formed on the one main surface of the substrate <NUM>, as shown in <FIG>. The multilayer reflection film and protection film can be formed, respectively, by an ion beam sputtering method, a CD sputtering method or an RF sputtering method. <FIG> illustrates an example where convex phase defects <NUM> are formed in the multilayer reflection film <NUM> and protection film <NUM>.

In step (B2), the defects in the multilayer reflection film <NUM> and protection film <NUM> are inspected. Positional information of the detected defects (the phase defects in this case) on the basis of coordinates defined with reference to the coordinate reference mark <NUM> is obtained, and the positional information is saved into a recording medium. A concrete method of inspecting for defects in this step is described later. In this defect inspection, it is preferable to obtain information of the detected signal level of the defect along with positional information, and to save them into the recording medium. In addition, a step of measuring the flatness of the substrate is included after step (B1) and before step (B2). The flatness is measured by utilizing a function for adjusting focus in an optical system for detecting the coordinate reference marks, of the e.g. inspection tool shown in <FIG> and described later.

In step (C1), an absorber film <NUM> is formed on the protection film <NUM>, as shown in <FIG>. The absorber film can also be formed by an ion beam sputtering method, a CD sputtering method or an RF sputtering method. In <FIG>, the absorber film <NUM> has a convex shape at the position of the phase defect <NUM> derived from the convex phase defect <NUM> formed in the multilayer reflection film <NUM> and protection film <NUM>. Besides, in this case, <FIG> illustrates also an example where a particle <NUM> is attached on the surface of the absorber film <NUM>.

In step (C2), defects in the formed absorber film, in which a phase defect in the multilayer reflective film, a particle defect, and other defects are included, are inspected, positional information of the detected defects on the basis of coordinates defined with reference to the coordinate reference mark <NUM> is obtained, and the positional information is saved into a recording medium. The defect inspection may be conducted by a conventionally known method in this step. For example, as shown in <FIG>, when a particle is attached on the surface of the absorber film, the defect is detected as a particle defect. The positional information of the detected defect is obtained, and saved into the recording medium. In addition, a step of measuring a flatness of the substrate is included after step (C1) and before step (C2).

A step of forming a resist film (photoresist film) on the absorber film may be included after step (C2). According to this method, a reflective mask blank RMB as shown in <FIG> is obtained. A reflective mask, for example, as shown in <FIG>, is manufactured by patterning the absorber film of the reflective mask blank.

Next, a suitable defect inspection method for the steps (B2) and (C2) is described. <FIG> is a conceptual diagram of an inspection tool including an optical system for detecting defects of a film formed on one main surface side of a substrate (a defect of the multilayer reflection film, particularly a phase defect in the step (B2), or a defect of the absorber film in the step (C2)), and an optical system for detecting a coordinate reference mark on another main surface side of the substrate. The inspection tool <NUM> includes a supporting member SPT for supporting a film-formed substrate FFS, a mask stage STG, a stage driving unit <NUM>, an optical system for defect inspection <NUM>, an imaging and controlling unit for the defect inspection <NUM>, an optical system for detecting a coordinate reference mark <NUM>, an imaging and controlling unit for detecting the coordinate reference mark <NUM>, and a control device <NUM> which controls the whole of the defect detection. In steps (B2) and (C2), an object designated the film-formed substrate FFS is usually an intermediate product in a process of manufacturing a reflective mask blank, or a reflective mask blank. However, an intermediate product in a process of manufacturing a reflective mask, or a reflective mask, may be applied as the object.

The optical system for defect inspection <NUM> and the optical system for detecting a coordinate reference mark <NUM> include an illumination optical system for irradiating inspection light and a system for focusing, respectively, although not shown in the drawing. The inspection light used in the optical system for defect inspection <NUM> may be inspection light having a wavelength of <NUM> to <NUM> which is applied usually, and further EUV light having a wavelength of <NUM> to <NUM> may also be applied. When EUV light is applied, a reflection-type mirror is used in the illumination optical system and the optical systems for inspection. As an optical system for detecting a coordinate reference mark formed on another main surface side of the substrate, for example, an optical system disclosed in <CIT> (Patent Document <NUM>) for a wafer substrate as an object is known, and it is also possible to use such an optical system.

In the case of the inspection tool shown in <FIG>, the optical system for defect inspection <NUM> and the optical system for detecting a coordinate reference mark <NUM> are arranged so that the axes of the lenses are coaxially aligned on the same axis. When a defect of the film is detected by the optical system for defect inspection <NUM>, having detected the coordinate reference mark <NUM> formed on another main surface side of the film-formed substrate FFS, the position of the defect can be obtained as positional information on the basis of the coordinates determined with reference to the coordinate reference mark, and the obtained positional information is saved or recorded into a recording medium. Further, information of the detected signal level of the defect may be obtained along with the positional information of the defect. In this case, the information of the detected signal level of the defect may be saved or written along with the positional information of the defect into the recording medium. The coordinate system may be either a two-dimensional coordinate system or a three-dimensional coordinate system.

In particular, when a defect, specifically a phase defect is detected, it is preferable to create a processing sequence for the defects, and to save or record the processing sequence into the recording medium along with the positional information. The processing sequence may be a priority for processing the defects that is determined on the basis of a printability of the detected defects. For example, in step (B2), when a phase defect is detected in a multilayer reflection film, an expected influence of reduction in reflectance (printability of the defect in use of the reflective mask) caused by the phase defect in the multilayer reflection film can be evaluated from the information of the detected signal level of the phase defect. And, the processing sequence may be created so that a defect evaluated as a defect having a large influence of the reduction in reflectance is given a prior ranking. In this case, this processing sequence may be a priority for processing defects, for example, a priority for covering the defect with an absorber pattern by patterning the absorber film to form the absorber pattern in manufacturing a reflective mask.

In the case of the inspection tool shown in <FIG>, the support member SPT does not have a structure in which the film-formed substrate FFS is fixed with pressing. The film-formed substrate FFS is simply supported by the support member SPT, and the film-formed substrate FFS is not subject to any pressure that deforms its shape.

A substrate is warped due to stress by forming a film such as a multilayer reflective film, a protection film, an absorber film, and other films. When the film-formed substrate is simply supported, as in the inspection tool shown in <FIG>, and inspected, the substrate has a deflection and is inspected in a state having the deflection. In many cases, the shape of warpage or deflection can be represented, for example, by a quadric curve as shown in <FIG>. In <FIG>, the curve P-P' illustrates the state of a main surface of a substrate having warpage or deflection. The symbol "L" represents a distance from one of the opposing corners of the substrate to the center of the substrate (i.e. "<NUM>×L" corresponds to a distance of a diagonal line), and the symbol "H" represents an amount (height) of warpage or deflection at the center of the substrate. From these values, a radius of curvature R (a distance from the symbol "O" represented as the center of curvature) can be calculated under an assumption that the shape of the main surface of the substrate is a quadric surface. The distance L and the height H may be obtained by measuring a flatness of the substrate.

In defect inspection, local inclination of the film-formed substrate causes positional difference between the one and the other main surfaces of the substrate. Therefore, it is preferable to determine or grasp warpage or deflection of the substrate on which the multilayer reflection film, the protection film, the absorber film, and any other films are formed, and to correct influence of the local inclination derived from the determined warpage or deflection. <FIG> is a cross-sectional view illustrating schematically the state of a substrate on which a film is formed, locally inclined by an angle θ. In this case, when the substrate <NUM>, the multilayer reflection film <NUM>, the protection film <NUM> and the conductive film <NUM> have the total thickness "T", a positional difference represented "T×sin θ" arises in the coordinates between the one and the other main surfaces. Thus, the difference may be corrected. The angle θ may be calculated from the shape of warpage or deflection drawn by a quadric surface, and the approximate position of the detected defect. Besides, the angle θ may be directly calculated based on the method described in <CIT> (Patent Document <NUM>).

The correction value can be calculated, for example, as follows. When a radius of curvature of a quadric surface, and coordinates of the defect with respect to original point (x=<NUM>, y=<NUM>) in a two-dimensional coordinate system defined with reference to the coordinate reference marks are, respectively, "R" and "x, y", a correction value "Δx" in x-direction and a correction value "Δy" in y-direction attributed from inclination of the angle θ are, respectively, Δx=(T/R)x and Δy=(T/R)y. When such correction is applied, information for correcting the position of the defect may be saved or recorded into a recording medium along with the positional information of the defect.

Positional information of the defect(s) in a reflective mask blank is saved or recorded into a recording medium along with information of the detected signal level of the defect(s), a processing sequence (priority) thereof, information for correcting the position of the defect(s), and optionally others. The reflective mask blank of the invention may be provided as a set of a reflective mask blank, as a main component, and a recording medium. According to the reflective mask blank combined with the recording medium, when a reflective mask is manufactured from the reflective mask blank, in patterning the absorber film, position and processing sequence of the defect(s) can be determined from the information saved or recorded in the recording medium.

Next, a method of manufacturing a reflective mask is described. An example of the method of manufacturing the reflective mask by patterning an absorber film of a reflective mask blank is described with reference to the flowchart shown in <FIG>.

First, a reflective mask blank and recording medium or a set including a reflective mask blank and a recording medium is prepared (Step S101). The reflective mask blank, as a main component, includes prescribed films formed on one and another main surface of a substrate, and a coordinate reference mark formed on the other main surface of the substrate. The recording medium stores or records positional information of a defect such as a phase defect on the basis of coordinates defined with reference to the coordinate reference mark, information of the detected signal level of the defect, a processing sequence (priority), information for correcting the position of the defect, and others. Examples of the recording medium include a medium recording information electrically or magnetically. The recording medium may be a paper medium on which information is written. Next, a coordinate system is configured with reference to the coordinate reference marks formed on the reflective mask blank, and position of the defect(s) in the reflective mask blank is determined in the coordinate system by reference to the positional information of the defect(s) stored in the recording medium (Step S <NUM>). The coordinate system may be either a two-dimensional coordinate system or a three-dimensional coordinate system.

Next, a drawing pattern data to form an absorber pattern by patterning the absorber film is prepared (Step S103). Next, position of the drawing pattern is compared with the position of the defect(s), and the feasibility or availability of processing the defect by retaining the absorber film as an absorber pattern portion (typically, the possibility of covering the defect with the absorber pattern) is evaluated in accordance with the priority stored in the recording medium in sequence (Step S <NUM>). At this stage, if the evaluation decides that there is no defect that can be processed, or the number of defects is relatively small, the entire drawing pattern to form the absorber pattern may be rearranged by moving or shifting it in a predetermined direction. Then, the procedure is returned to Step S103, and the drawing position of the drawing pattern can be optimized by conducting Step S <NUM> again. By this way, it is possible to optimize the drawn position of the drawing pattern so as to maximize the coverage of defect(s) having a high priority that have a high fatality and should be preferentially covered with the absorber pattern, among the defects. In addition, influence of a local inclination derived from the warpage or deflection of the substrate may be also corrected for the drawn position of the drawing pattern as same in correction of the defect position with respect to the local inclination of the film-formed substrate.

The drawing pattern may be set on the basis of coordinates defined with reference to the coordinate reference mark. For the purpose, a tool for writing the drawing pattern preferably has a function that detects the coordinate reference mark. If the drawing tool does not have a function for detection of the coordinate reference mark, or the coordinate reference mark cannot be detected, preliminarily, an auxiliary mark may be formed on the periphery of the absorber film by the drawing tool to utilize the auxiliary mark for the setting. A fiducial mark may be utilized as the auxiliary mark. In this case, a coordinate system defined via the auxiliary mark with reference to the coordinate reference mark may be configured by obtaining the relationship between the coordinate reference mark and the auxiliary mark by means of, for example, an inspection tool as shown in <FIG>.

Next, the absorber pattern is formed by patterning the absorber film (Step S105). In particular, the absorber pattern may be formed by etching and removing a part of the absorber film of the reflective mask blank so as to leave the absorber film as a portion of the absorber pattern at the position of a defect that has been evaluated as a processable defect, in accordance with the position of the defect in the coordinate system.

By this manufacturing method of the reflective mask, the absorber pattern can be formed so that influence of such a defect (phase defect) or defects is mitigated as much as possible, and a reflective mask having a controlled or limited influence of such defects can be manufactured. Further, when the reflective mask can be manufactured by such a method, it is not necessarily to completely eliminate defects such as a phase defect of the reflective mask blank, to zero. Therefore, by this method, yield of reflective mask blanks that can be used for manufacturing a reflective mask is effectively increased, and reflective mask blanks can be provided with good productivity.

The reflective mask obtained by patterning the absorber film to form the absorber pattern is normally subjected to inspection for pattern defects of the absorber pattern (Step S106). If needed, repair or shape correction of the absorber pattern is conducted. Conventionally known methods may be applied for these, and the coordinates defined with reference to the coordinate reference mark of the invention are preferably utilized in the inspection of defect of the absorber pattern, or the repair or shape correction of the absorber pattern.

After the inspection of pattern defect of the absorber pattern, for example, as shown in <FIG>, the possibility of there remaining a fatal defect, particularly a fatal phase defect, in the reflective mask is evaluated with reference to the inspected defect information of the absorber pattern, the positional information of the defect stored in the recording medium, and the positional information of the drawing pattern (Step S107). Next, if such a fatal defect remains, a correction amount is calculated to correct the shape of the absorber pattern (Step S108), and a need for repairing the absorber pattern in accordance with the inspected defect information of the absorber pattern, and a need for correcting the shape of the absorber pattern at the fatal defect are evaluated (Step S109). On the other hand, when it is evaluated in Step S107 that the absorber pattern is free of such a fatal defect, Step S109 is directly conducted (without Step S108), and the need for repairing the absorber pattern in accordance with the inspected defect information of the absorber pattern is evaluated. Next, when it is evaluated that repairing of the absorber pattern in accordance with the inspected defect information of the absorber pattern, or correcting the shape of the absorber pattern for the fatal defect is necessary, the repair or shape correction of the absorber pattern is conducted (Step S110).

Here, the shape correction of the absorber pattern is described by illustrating the absorber pattern of the reflective mask and the positions of phase defects existing in a multilayer reflection film. <FIG> are, respectively, conceptual diagrams illustrating an absorber pattern of a reflective mask and positions of phase defects existing in a multilayer reflection film. In both <FIG>, phase defects 120a having a high priority are completely covered by the absorber pattern <NUM>, and the phase defect 120a having a high priority is in a state in which it does not project as a defect when the reflective mask is used. On the other hand, for example, a phase defect 120b that has a low priority and has not been covered with the absorber pattern <NUM> may remain in some cases. If the number of defects is large, the probability of there remaining a phase defect 120b that is not covered with the absorber pattern <NUM> increases. Further, if a positional error arises when forming the absorber film pattern, a high priority phase defect 120b that is not covered with the absorber pattern <NUM> may remain.

When such a remaining phase defect is a phase defect existing between adjacent absorber pattern portions, the influence in projecting mask pattern by an exposure tool can be mitigated, for example, by the method disclosed in <CIT> (Patent Document <NUM>), in particular, the method of correcting (modifying) the contour of the absorber pattern adjacent to the phase defect.

Examples of the invention are given below by way of illustration and not by way of limitation.

First, a substrate was prepared and a conductive film (<NUM> thick) composed of Cr-based material was formed on another main surface of the substrate. Next, a cross-form mark as shown in <FIG> was formed in each of the four mark-formation areas of the conductive film shown in <FIG>, to constitute a coordinate reference mark comprising four marks. The coordinate reference mark was a concave mark having a depth of <NUM> formed by etching and removing the conductive film by means of photolithography. The width of the line was <NUM>, and the lengths of the crossed lines were <NUM>, respectively.

Next, after cleaning the substrate, a multilayer reflection film (<NUM> thick) including <NUM> molybdenum (Mo) layers and <NUM> silicon (Si) layers that were laminated alternately were formed on one main surface of the substrate. Further, a protection film (<NUM> thick) composed of a material containing ruthenium as a main component was formed on the multilayer reflection film.

Next, defect inspection was conducted on the substrate on which the multilayer reflection film and protection film were formed, by an inspection tool as shown in <FIG>. First, an origin point (x=<NUM>, y=<NUM>) for a two-dimensional x-y coordinate system was set at the central portion of the other main surface of the substrate. Next, before defect inspection of the multilayer reflection film and protection film, a warpage or deflection of the substrate was measured as a flatness by means of a function for adjusting the focus of an optical system ued for detection of the coordinate reference mark. As a result, it was found that the center of the substrate was warped upward compared to the outer periphery of the substrate. The measured substrate had a length L of <NUM> and a height H of <NUM>, respectively, which are indicated in <FIG>. Thus, the radius of curvature R of the warpage was <NUM>×<NUM><NUM> mm.

In this defect inspection, first, a phase defect in the multilayer reflection film was inspected, and the position of the defect was obtained on the two-dimensional x-y coordinate of the other main surface. The position of the defect was corrected with the radius of curvature R that had been obtained to modify the warpage or deflection of the substrate, and the positional information of the defect was saved into a recording medium along with information of the detected signal level of the defect. Next, after inspecting the multilayer reflection film over the whole of the predetermined area, a priority for processing defects was determined in accordance with information of the defect stored in the recording medium, and the priority was also saved into the recording medium.

Next, an absorber film (<NUM> thick) composed of a material containing tantrum (Ta) as a main component was formed on the protection film.

Next, defect inspection was conducted on the substrate on which the absorber film was formed by the inspection tool shown in <FIG>. First, before defect inspection of the absorber film, a warpage or deflection of the substrate was measured as a flatness by means of the function for adjusting focus of the optical system for detection of the coordinate reference mark. As a result, it was found that the center of the substrate was warped upward compared to the outer periphery of the substrate. The measured substrate had a length L of <NUM> and a height H of <NUM>, respectively, as indicated in <FIG>. Thus, the radius of curvature R of the warpage was <NUM>×<NUM><NUM> mm.

In this defect inspection, first, a phase defect in the absorber film was inspected, and the position of the defect was obtained on the two-dimensional x-y coordinate of the other main surface. The position of the defect was corrected using the radius of curvature R that had been obtained to modify the warpage or deflection of the substrate, and the positional information of the defect was saved into a recording medium along with information of the detected signal level of the defect. By the method, a reflective mask blank was obtained.

Next, a reflective mask was manufactured in accordance with procedure in the flow chart described in <FIG>. First, a combination (set) of the reflective mask blank as a main component and the recording medium was prepared. An electron beam resist was coated on the surface of the blank, then, the blank was mounted on the mask stage of an electron beam drawing tool. Next, coordinate positions of the defects stored in the recording medium were determined with reference to the coordinate reference marks. Next, drawing pattern data for the absorber film were prepared, and the drawing position of the absorber pattern was optimized so as to cover the maximum number of defects in accordance with the priority stored in the recording medium. Then, the optimally arranged drawing pattern was drawn onto the electron beam resist as the absorber pattern, and the absorber pattern was formed by the usual manner.

In this case, since the manufacturing process from the reflective mask blank to the reflective mask was conducted using the coordinate reference marks formed on the other main surface of the substrate in common, positions of the defects were determined with high accuracy. Thus, the error of position detection was within <NUM>.

After a conductive film the same as in Example <NUM> was formed on the other main surface of a substrate, coordinate reference marks the same as in Example <NUM> were formed on the one main surface of the substrate by an ordinary lithography method, without forming coordinate reference marks in the conductive film on the other surface. Next, a multilayer reflection film, protection film and absorber film the same as in Example <NUM> were formed on the one main surface of the substrate, so that a reflective mask blank was obtained. The measurements of flatness (modifications of warpage or deflection) and the defect inspection in manufacture of the reflective mask blank were conducted as in Example <NUM>. A reflective mask was manufactured from the resulting reflective mask blank by the same method as in Example <NUM>.

In this case, the films having a total thickness of about <NUM> had been formed on the coordinate reference marks at the stage after forming the multilayer reflection film and protection film, and films having a total thickness of about <NUM> had been formed on the coordinate reference marks at the stage after further forming the absorber film. Since a resist film is formed on the absorber film in manufacturing a reflective mask, the positions of the defects were determined with less accuracy compared to Example <NUM>. Thus, an error of position detection within <NUM> was not attained.

In respect of numerical ranges disclosed in the present description it will of course be understood that in the normal way the technical criterion for the upper limit is different from the technical criterion for the lower limit, i.e. the upper and lower limits are intrinsically distinct proposals.

Claim 1:
A method of manufacturing a reflective mask blank, the mask blank comprising
a substrate (<NUM>),
a multilayer reflection film (<NUM>) for EUV light reflection, a protection film (<NUM>), and an absorber film (<NUM>) for EUV light absorption formed on one main surface of the substrate, in that order from the substrate side, and
a conductive film (<NUM>) formed on the other main surface of the substrate, the method comprising the steps of:
(A1) forming the conductive film (<NUM>) on said other main surface,
(A2) forming a coordinate reference mark (<NUM>) on said other main surface side,
(B1) forming the multilayer reflection film (<NUM>) and protection film (<NUM>) on said one main surface, measuring the flatness of the substrate (<NUM>) by measuring a warpage or deflection of the substrate by a function for adjusting the focus of an optical system used for detection of the coordinate reference mark,
(B2) inspecting for defects in the multilayer reflection film and protection film formed in step (B1), obtaining positional information of a detected defect on the basis of coordinates defined with reference to the coordinate reference mark (<NUM>), correcting the position of the defect based on the determined warpage or deflection, and saving the positional information into a recording medium,
(C1) after step (B2), forming the absorber film (<NUM>) on the protection film (<NUM>), measuring the flatness of the substrate (<NUM>) by the method in step (B1), and
(C2) inspecting for defects in the absorber film (<NUM>) formed in step (C1), obtaining positional information of a detected defect on the basis of coordinates defined with reference to the coordinate reference mark (<NUM>), correcting the position of the defect based on the determined warpage or deflection in step (C1), and saving the positional information into a recording medium.