U.S. patent application number 11/274676 was filed with the patent office on 2006-03-30 for exposure method.
Invention is credited to Miyoko Kawashima.
Application Number | 20060068331 11/274676 |
Document ID | / |
Family ID | 29706669 |
Filed Date | 2006-03-30 |
United States Patent
Application |
20060068331 |
Kind Code |
A1 |
Kawashima; Miyoko |
March 30, 2006 |
Exposure method
Abstract
An exposure method includes the steps of providing a mask that
arranges a contact-hole pattern and a pattern smaller than the
contact-hole pattern, and illuminating the mask using plural kinds
of light so as to resolve the contact-hole pattern and restrain the
smaller pattern from resolving on an object to be exposed via a
projection optical system, wherein the following conditions are met
A=-1.7k.sub.1+C1, 1.2.ltoreq.C1.ltoreq.1.3,
0.5.ltoreq.B.ltoreq.0.55 and B.ltoreq.A-0.1,
0.80.ltoreq..sigma..ltoreq.0.9 and .sigma..gtoreq.A+0.1,
k.sub.1=(L/.lamda.) NA, where k.sub.1 is resolving power, L is a
hole diameter of the contact-hole pattern, .lamda. is a wavelength
for exposure, NA is a numerical aperture of the projection optical
system, .sigma. is a ratio of a numerical aperture of an
illumination optical system to the numerical aperture of the
projection optical system, A and B are distances from two
orthogonal axes to a boarder of a light-shielding part in an
effective light source for illumination of plural kinds of light,
the light-shielding part being symmetrical with respect to the two
orthogonal axes.
Inventors: |
Kawashima; Miyoko; (Tochigi,
JP) |
Correspondence
Address: |
MORGAN & FINNEGAN, L.L.P.
3 WORLD FINANCIAL CENTER
NEW YORK
NY
10281-2101
US
|
Family ID: |
29706669 |
Appl. No.: |
11/274676 |
Filed: |
November 14, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10456387 |
Jun 5, 2003 |
6991896 |
|
|
11274676 |
Nov 14, 2005 |
|
|
|
Current U.S.
Class: |
430/311 ;
430/396 |
Current CPC
Class: |
G03F 7/70433 20130101;
G03F 1/36 20130101 |
Class at
Publication: |
430/311 ;
430/396 |
International
Class: |
G03F 7/00 20060101
G03F007/00; G03F 7/20 20060101 G03F007/20 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 5, 2002 |
JP |
164978/2002 |
Claims
1. An exposure method comprising the steps of: providing a mask
that arranges a contact-hole pattern and a pattern smaller than the
contact-hole pattern; and illuminating the mask using plural kinds
of light so as to resolve the contact-hole pattern and restrain the
smaller pattern from resolving on an object to be exposed via a
projection optical system, wherein 0.7.ltoreq.d/t.ltoreq.0.80 is
met where d is a size of an opening in the smaller pattern, and t
is a size of an opening in the contact-hole pattern.
2. An exposure method according to claim 1, wherein
0.85L.ltoreq.t.ltoreq.1.15L is met where L is a hole diameter of
the contact-hole pattern.
3. An exposure method comprising the steps of: providing a mask
that arranges a contact-hole pattern and a pattern smaller than the
contact-hole pattern; and illuminating the mask using plural kinds
of light so as to resolve the contact-hole pattern and restrain the
smaller pattern from resolving on an object to be exposed via a
projection optical system, wherein 0.75.ltoreq.d/t.ltoreq.0.90 is
met where d is a size of an opening in the smaller pattern, and
smaller than 0.45 when converted into resolving power k.sub.1, and
t is a size of an opening in the contact-hole pattern.
4. An exposure method according to claim 3, wherein
0.85L.ltoreq.t.ltoreq.1.15L is met where L is a hole diameter of
the contact-hole pattern.
5. An exposure method comprising the steps of: providing a mask
that arranges a contact-hole pattern and a pattern smaller than the
contact-hole pattern; and illuminating the mask using plural kinds
of light so as to resolve the contact-hole pattern and restrain the
smaller pattern from resolving on an object to be exposed via a
projection optical system, 0.85L.ltoreq.t.ltoreq.1.15L is met where
L is a hole diameter of the contact-hole pattern.
6. A device manufacturing method comprising the steps of: exposing
a pattern formed on a reticle onto an object by using an exposure
method; and performing a predetermined process for the exposed
object, wherein the exposure method includes the steps of providing
a mask that arranges a contact-hole pattern and a pattern smaller
than the contact-hole pattern, and illuminating the mask using
plural kinds of light so as to resolve the contact-hole pattern and
restrain the smaller pattern from resolving on an object to be
exposed via a projection optical system, wherein
0.7.ltoreq.d/t.ltoreq.0.80 is met where d is a size of an opening
in the smaller pattern, and t is a size of an opening in the
contact-hole pattern.
7. A device manufacturing method comprising the steps of: exposing
a pattern formed on a reticle onto an object by using an exposure
method; and performing a predetermined process for the exposed
object, wherein the exposure method includes the steps of providing
a mask that arranges a contact-hole pattern and a pattern smaller
than the contact-hole pattern, and illuminating the mask using
plural kinds of light so as to resolve the contact-hole pattern and
restrain the smaller pattern from resolving on an object to be
exposed via a projection optical system, wherein
0.75.ltoreq.d/t.ltoreq.0.90 is met where d is a size of an opening
in the smaller pattern, and t is a size of an opening in the
contact-hole pattern.
Description
[0001] This application claims the right of priority under 35
U.S.C. .sctn. 119 based on Japanese Patent Application No.
2002-164978, filed on Jun. 5, 2002, which is hereby incorporated by
reference herein in its entirety as if fully set forth herein.
[0002] This is a continuation of co-pending application Ser. No.
10/456,387, filed on Jun. 5, 2003, which is hereby incorporated by
reference herein in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0003] The present invention relates generally to a mask pattern
and a method for setting an optimal illumination condition to the
mask pattern, and more particularly to a mask pattern and a method
for setting an illumination condition suitable of a method of
exposing a mask that arranges a desired pattern and an auxiliary or
dummy pattern (these terms are used interchangeably in this
application) smaller than the desired pattern, by illuminating the
mask (reticle) using plural kinds of light so as to resolve the
desired pattern and restrain the auxiliary pattern from resolving
on an object to be exposed via a projection optical system.
[0004] The projection exposure apparatus is used in manufacturing
devices, such as ICs, LSIs and liquid crystal panels, using the
photolithography. For improved resolution, the projection exposure
apparatus has generally shortened its exposure wavelength and
enlarged a numerical aperture ("NA") in the projection optical
system.
[0005] In general, the resolving power improves with a shortened
wavelength of exposure light and increased NA, while the projection
exposure apparatus, from its nature, resolves some patterns
relatively easily but cannot resolve other patterns easily. In
general, it may be said that a line pattern more easily resolves
than a contact-hole pattern, and thus a width in the contact-hole
pattern is larger than that of the line pattern in a semiconductor
chip. It is therefore an issue in fine processing in the
photolithography to make a fine contact-hole pattern. More
specifically, exposure cannot easily obtain the resolving power,
depth of focus ("DOF"), and exposure dose tolerance for contact
holes. In addition, the contact holes have a much larger mask error
enhancement factor ("MEF") that is a degree to emphasize a mask
error, than the line pattern, which hinders fine processing.
[0006] Accordingly, Japanese Patent No. 3,119,217 (corresponding to
U.S. Pat. No. 6,150,059) as one solution for this problem discloses
a method to improve resolving power and DOF to some extent by
forming, among openings, auxiliary openings so dimensioned that
they are not resolved by exposure. Japanese Laid-Open Patent
Application No. 2002-122976 (corresponding to U.S. Patent
Application Publication No. 2002-045136) provides more concrete
embodiments to this method.
[0007] These methods are effective to resolve contact holes of
about 200 nm as in their embodiments but insufficient to resolve
currently demanded 120 nm contact holes. More specifically, when
the resolving power to 200-nm holes is converted into resolving
power k.sub.1 for exposure using a general exposure apparatus at
the time of filing of these applications which uses, for example, a
KrF laser light source and NA=0.6 to 0.5, k.sub.1 becomes between
0.48 and 0.40. This conversion is performed with k.sub.1=(hole
diameter of a desired contact hole)/(.lamda./NA) as a variation of
Rayleigh's equation: (hole diameter of a desired contact
hole)=k.sub.1(.lamda./NA). This converted k.sub.1 value corresponds
to the resolving power of 163 to 136 nm for exposure using a
currently available general exposure apparatus which uses, for
example, a KrF laser light source and NA=0.73. It is therefore
understood that the methods disclosed in these applications may
resolve holes with a size of 163 to 136 nm, but cannot resolve
holes with a size of 120 nm or smaller. Incidentally, 163 nm and
136 nm may be obtained as follows: (hole diameter of a desired
contact hole)=k.sub.1(.lamda./NA)=0.48.times.248/0.73=163 (nm) for
k.sub.1=0.48, while (hole diameter of a desired contact
hole)=k.sub.1(.lamda./NA)=0.40.times.248/0.73=136 (nm) for
k.sub.1=0.40.
BRIEF SUMMARY OF THE INVENTION
[0008] Accordingly, it is an exemplified object of the present
invention to provide an exposure method for resolving fine contact
holes of 120 nm or smaller with resolving power k.sub.1=0.35 under
practical DOF, using a current typical exposure apparatus that uses
a KrF laser light source with an approximately wavelength of 248 nm
and NA=0.73.
[0009] Japanese Patent Application No. 2002-123268 (corresponding
to U.S. patent application Ser. No. 10/132,001, filed on Apr. 24,
2002) proposes, for the resolving power k.sub.1=0.35 or smaller, an
exposure method for exposing a mask that arranges a contact-hole
pattern and a pattern smaller than the contact-hole pattern, by
illuminating the mask using plural kinds of light so as to resolve
the contact-hole pattern and restrain the smaller pattern from
resolving on an object to be exposed via a projection optical
system. It is a more specific object of the present invention to
obtain larger process tolerance including DOF and exposure dose or
establish a stable process less influenced by the mask errors and
exposure conditions, such as a change of exposure dose and a
defocus error.
[0010] An exposure method of one aspect of the present invention
includes the steps of providing a mask that arranges a contact-hole
pattern and a pattern smaller than the contact-hole pattern, and
illuminating the mask using plural kinds of light so as to resolve
the contact-hole pattern and restrain the smaller pattern from
resolving on an object to be exposed via a projection optical
system, wherein A=-1.7k.sub.1+C1, 1.2.ltoreq.C1.ltoreq.1.3,
0.5.ltoreq.B.ltoreq.0.55 and B.ltoreq.A-0.1,
0.80.ltoreq..sigma..ltoreq.0.9 and .sigma..gtoreq.A+0.1,
k.sub.1=(L/.lamda.) NA, where k.sub.1 is resolving power, L is a
hole diameter of the contact-hole pattern, k is a wavelength for
exposure, NA is a numerical aperture of the projection optical
system, .sigma. is a ratio of a numerical aperture of an
illumination optical system to the numerical aperture of the
projection optical system, A and B are distances from two
orthogonal axes to a boarder of a light-shielding part in an
effective light source for illumination of plural kinds of light,
the light-shielding part being symmetrical with respect to the two
orthogonal axes.
[0011] Conditions A=-1.7k.sub.1+1.25, k.sub.1.ltoreq.0.4, B=0.55,
.sigma.=0.85 may be met irrespective of the hole diameter. An
exposure method of the present invention includes the steps of
providing a mask that arranges a contact-hole pattern and a pattern
smaller than the contact-hole pattern, and illuminating the mask
using plural kinds of light so as to resolve the contact-hole
pattern and restrain the smaller pattern from resolving on an
object to be exposed via a projection optical system, wherein
A=1/(4k.sub.1)-C2/(4k.sub.1).sup.2, 0.07.ltoreq.C2.ltoreq.0.20,
0.5.ltoreq.B.ltoreq.0.55 and B.ltoreq.A-0.1,
0.80.ltoreq..sigma..ltoreq.0.9 and .sigma..gtoreq.A+0.1,
k.sub.1=(L/.lamda.)NA, where k.sub.1 is resolving power, L is a
hole diameter of the contact-hole pattern, .lamda. is a wavelength
for exposure, NA is a numerical aperture of the projection optical
system, .sigma. is a ratio of a numerical aperture of an
illumination optical system to the numerical aperture of the
projection optical system, A and B are distances from two
orthogonal axes to a boarder of a light-shielding part in an
effective light source for illumination of plural kinds of light,
the light-shielding part being symmetrical with respect to the two
orthogonal axes.
[0012] The effective light source has a shape shown in FIG. 1 or
4.
[0013] An exposure method of still another aspect of the present
invention includes the step of providing a mask that arranges a
contact-hole pattern and a pattern smaller than the contact-hole
pattern, and the step of illuminating the mask using plural kinds
of light so as to resolve the contact-hole pattern and restrain the
smaller pattern from resolving on an object to be exposed via a
projection optical system, wherein 0.7.ltoreq.d/t.ltoreq.0.80 is
met where d is a size of an opening in the smaller pattern, and t
is a size of an opening in the contact-hole pattern.
[0014] An exposure method of another aspect of the present
invention include the step of providing a mask that arranges a
contact-hole pattern and a pattern smaller than the contact-hole
pattern, and the step of illuminating the mask using plural kinds
of light so as to resolve the contact-hole pattern and restrain the
smaller pattern from resolving on an object to be exposed via a
projection optical system, wherein 0.75.ltoreq.d/t.ltoreq.0.90 is
met where d is a size of an opening in the smaller pattern, and t
is a size of an opening in the contact-hole pattern.
[0015] A condition 0.85L.ltoreq.t.ltoreq.1.15L may be met where L
is a hole diameter of the contact-hole pattern.
[0016] A device fabricating method of still another aspect of the
present invention includes the step of exposing an object using the
above exposure method, and performing a predetermined process for
the exposed object. Claims for a device fabricating method that
performs operations similar to that of the above exposure apparatus
cover devices as intermediate and final products. Such devices
include semiconductor chips like an LSI and VLSI, CCDs, LCDs,
magnetic sensors, thin film magnetic heads, and the like.
[0017] Other objects and further features of the present invention
will become readily apparent from the following description of the
preferred embodiments with reference to accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic plane view of an effective light
source shape used for an exposure method according to the present
invention.
[0019] FIG. 2 is a schematic plane view of a mask pattern used for
the inventive exposure method.
[0020] FIG. 3 is a desired image pattern when the mask pattern
shown in FIG. 2 images.
[0021] FIG. 4 is a schematic plane view as a variation of an
effective light-source shape shown in FIG. 1.
[0022] FIG. 5 is a schematic plane view of one example of an
effective light-source shape unsuitable for the inventive exposure
method.
[0023] FIG. 6 is a schematic plane view of another example of an
effective light-source shape unsuitable for the inventive exposure
method.
[0024] FIG. 7 is a table showing a relationship between pattern
bias and critical dimension error deviation.
[0025] FIG. 8 is a table showing a relationship between pattern
bias and mask enhancement factor.
[0026] FIG. 9 is a table showing a relationship between pattern
bias and depth of focus.
[0027] FIG. 10 is a graph for showing a relationship between a half
pitch in a mask pattern and the mask enhancement factor.
[0028] FIG. 11 is a graph for showing a relationship between the
mask enhancement factor and effective light-source parameters.
[0029] FIG. 12 is a graph for showing a relationship between the
depth of focus and effective light-source parameters.
[0030] FIG. 13 is a graph for showing a relationship between the
mask enhancement factor and effective light-source parameters.
[0031] FIG. 14 is a graph for showing a relationship between the
depth of focus and effective light-source parameters.
[0032] FIG. 15 is a graph for showing a relationship between a
depth of focus and effective light-source parameters when exposure
dose changes by 5%.
[0033] FIG. 16 is an exposure test result of one embodiment
according to the present invention.
[0034] FIG. 17 is a process window showing a relationship between
the exposure dose and defocus amount.
[0035] FIG. 18 is a schematic block diagram of an exposure
apparatus used for one embodiment according to the present
invention.
[0036] FIG. 19 is a flowchart for explaining a device fabricating
method using the exposure apparatus of the present invention.
[0037] FIG. 20 is a detailed flowchart for step 4 shown in FIG.
19.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] It is an exemplary object to optimize parameters for an
exposure method for exposing with a mask that arranges a
contact-hole pattern and a pattern smaller than the contact-hole
pattern, by illuminating the mask using plural kinds of light so as
to resolve the contact-hole pattern and restrain the smaller
pattern from resolving on an object to be exposed via a projection
optical system. The parameters include a size or hole diameter L of
the contact-hole pattern to be finally formed on an image plane, a
size "t" of each hole in the mask pattern to be resolved, a size
"d" of a dummy or auxiliary opening not to be resolved, a parameter
a in an effective light source shown in FIG. 1, which will be
described later, i.e., a ratio of a NA of an illumination optical
system to the NA of the projection optical system, and sizes A and
B of central light-shielding part.
[0039] FIG. 3 shows an exemplary desired pattern to be resolved. A
size of the opening is 120 nm or smaller. The mask pattern size has
four or five times as large as the desired size according to the
magnification of the exposure apparatus, but this embodiment
converts the size into that on the image plane or without taking
the magnification into consideration. A binary mask has a mask
pattern and light-shielding part around the mask pattern, as shown
in FIG. 2. While the following description uses the binary mask as
an exemplary mask, the mask may use an attenuated phase shift mask
that allows light-shielding part to slightly transmit the light and
shifts its light phase by 180 degrees from that of opening part.
The mask pattern includes a desired pattern shown in FIG. 3 and
unresolved auxiliary openings around the desired pattern. The
auxiliary openings are positioned determined such that the desired
pattern and auxiliary openings form periodicity. Although the
desired pattern and auxiliary opening are illustrated as square
shapes in the drawing, they are not limited to a square shape and
may use a octagon that has been formed by chamfering corners of the
square, a circle, and any other shape.
[0040] As shown in FIG. 2, an opening size of the pattern is set to
"t" for a contact-hole size to be resolved, and "d" for an
auxiliary opening not to be resolved. The resolving power k.sub.1
in this case may be standardized using an exposure wavelength
.lamda. to expose the wafer and an NA of the projection optical
system expressed as a modification of Rayleigh's equation as
follows: Resolving Power k.sub.1=(L/.lamda.)NA where L is a size or
hole diameter of the contact-hole pattern to be finally
obtained.
[0041] The illumination system in the exposure apparatus forms an
effective light source as shown in FIG. 1. In FIG. 1, black part is
light-shielding part while white part is light-transmitting part. A
shape of the light source is determined by ".sigma." as a ratio of
a NA of an illumination optical system to the NA of the projection
optical system, and sizes A and B of the central light-shielding
part. A shape of the effective light source is not limited to FIG.
1, but may use a shape shown in FIG. 4 that notches corners or a
shape that allows the light to slightly cross the boarder of the
light-shielding area.
[0042] It is necessary to initially determine a size "t" of each
hole in the mask pattern to be resolved, and a size "d" of a dummy
or auxiliary opening not to be resolved. The method disclosed in
Japanese Patent No. 3,119,217 provides auxiliary openings of 150 nm
to resolve openings of 200 nm, while the method disclosed in
Japanese Laid-Open Patent Application No. 2002-122976 provides
auxiliary openings of 140 nm to resolve openings of 200 nm. The
size of the auxiliary opening is about seven-tenths of the main
opening, but the way of determining it is indefinite.
[0043] This embodiment sets a shape of the effective light source
with .sigma.=0.9, A=0.7 and B=0.5. Influences on the critical
dimension ("CD") distribution, MEF and DOF have been investigated
using the opening size t and auxiliary opening size d. The pattern
has a size of 120 nm shown in FIG. 3, and diameters of nine holes
on the image plane exposed by the exposure apparatus have been
investigated. The exposure dose this time is determined so that the
lower left hole shown in FIG. 3 has a desired size of 120 nm. A
deviation of the size of CD of the other eight holes from 120 nm
(L:desired size) is calculated as a ratio of a difference (%) by
dividing the difference by the desired size. The maximum CDi is
defined as the CD deviation since the size deviates within this
value: CDi=(CD-L)/L-100 [0044] CD deviation=maximum value of
CDi
[0045] MEF is a standardized index formed by dividing a difference
between a size (CD) of a pattern on the image plane without any
error in a mask pattern and a size (CD') of a pattern on the image
plane with a certain error (CD_mask_error) in the mask pattern, by
the error amount applied to the mask pattern. [0046] Change in
Pattern Size on Image plane CD_error=CD'-CD [0047]
MEF=CD_error/CD_mask_error
[0048] An error amount is given in longitudinal and lateral
directions to the mask pattern while a size of the nine major
openings is made equal to that of auxiliary openings, and the image
includes nine different sizes in the longitudinal and lateral
directions. MEF was calculated by dividing the maximum size change
by the error amount.
[0049] An image-plane position is defocused in exposure, size
changes of nine holes are investigated, and DOF is defined as the
minimum defocus amount value when the sizes of nine holes change by
10% from the size at the best focus. Results are indicated in FIGS.
7, 8 and 9. In these figures, a size change in the lateral
direction indicates a size change of the major opening "t"
(including 100%, 105%, 110% and 115% of the desired size from the
left) and a size change in the longitudinal direction indicates a
size change of the auxiliary opening "d" (including 75%, 80%, 85%,
90% and 95% of the desired size from the bottom).
[0050] According to the CD deviation result shown in FIG. 7, the CD
deviation becomes smaller with the larger size d of the auxiliary
opening and the larger size t of the major opening. The smaller CD
deviation is desirable. Conversely, according to the MEF result
shown in FIG. 8, the MEF becomes smaller with the smaller size d of
the auxiliary opening and a larger difference in size t of the
major opening. The smaller MEF is desirable. According to the MEF
result shown in FIG. 9, the DOF becomes larger with the larger size
d of the auxiliary opening close to the size t of the major
opening. The larger DOF is desirable. Therefore, MEF and CD
deviation or DOF show preferable results in reverse directions.
[0051] The CD deviation may be corrected by expecting the size
change on the mask pattern in advance, but the DOF and mask error
sensitivity or MEF are both important factors and cannot sacrifice
the other. Here, as understood from the figures, a MEF value is at
most 3.2 or smaller in the varying auxiliary opening size d and
major opening size t. Since the contact-hole process may permit a
MEF value of 3.5 or smaller, the DOF takes precedence such that a
ratio d/t between the auxiliary-opening size d and the
major-opening size t meets 0.75.ltoreq.d/t.ltoreq.0.9. The upper
limit is the maximum auxiliary-opening size such that the auxiliary
opening does not appear on the image plane, and this value slightly
changes according to types of resist.
[0052] As the hole size of the desired pattern is made smaller down
to 110 nm (with k.sub.1=0.32), and d/t exceeds 80%, MEF exceeds 3.5
although MEF is slightly variable depending upon the effective
light-source parameters. Therefore, practical MEF and DOF are
obtained when d/t is set to be 0.7.ltoreq.d/t.ltoreq.0.8 by taking
MEF into consideration. When the effective light-source parameters
vary, values of the MEF and DOF vary although relative
relationships between d/t as a ratio of opening sizes and MEF, and
d/t and DOF do not change.
[0053] However, this range of d/t is valid under the effective
light-source shape like in FIG. 1 because the MEF has a large value
and appropriate DOF is unavailable for any d/t without the
effective light-source shape like FIG. 1.
[0054] This range of d/t is particularly effective to fine hole
whose hole diameter meets k.sub.1.ltoreq.0.4.
[0055] Irrespective of the above optimal ratio, the way of actually
setting d and t depends upon a type of resist. The conventional
exposure result empirically tells that the resist of exclusive use
for holes provides a better result when the major-opening size t is
close to the desired pattern size, while the resist used for line
and space provides a better result when the major-opening size t is
1.1 times as large as that of the desired pattern size. Preferably,
the major-opening size t is 0.8 to 1.15 times as large as that of
the desired size L. Of course, an actual opening size on the mask
corresponds to this size multiplied by a reciprocal of the
magnification of the projection optical system.
[0056] The parameters of effective light-source shape are optimized
by setting the auxiliary-opening size d to be 80% of the desired
size, the major-opening size t to be 100% of the desired size, and
a ratio d/t to be 0.8. Usual contact-holes include only one type of
hole diameter or plural types of hole diameters within a limited
range of hole diameters. The number of holes different in size, if
any, is small. The pattern includes various intervals, e.g., an
interval that has the same as the hole diameter to form one-to-one
arrangement, an interval smaller than the hole diameter, an
interval twice as long as the hole diameter, and an interval three
times or more as long as the hole diameter or enough long to
isolate the pattern. In general, the typical contact-hole pattern
includes only one type of hole diameter and various intervals or
pitches between holes. Thus, the instant embodiment investigates
the MEF with only one type of hole diameter and variable pitches or
intervals between holes in order to recognize general tendency of
MEF.
[0057] FIG. 10 shows a change of MEF when the pitch varies with a
hole diameter of 120 nm under the effective light-source shape of
.sigma.=0.9, A=0.7 and B=0.5. In FIG. 10, the MEF value increases
when the pitch is smaller than the half pitch of 130 nm (with
k.sub.1=0.38) or pitch of 260 nm. This tendency does not change
even when parameters (.sigma., A, B) change anyway.
[0058] The fact that the MEF becomes the largest with the minimum
pitch means that only the MEF with the minimum pitch on a mask may
be considered in order to optimize the effective light-source
parameters .sigma., A and B and thereby minimize the MEF, since the
MEF is small with the minimum pitch and smaller with the larger
pitch.
[0059] Therefore, a pattern is used with the minimum pitch for
optimization, which equalizes the half pitch to the hole diameter
or has duty of 1 between the hole diameter and the interval.
[0060] Initially, a change of the MEF is investigated by varying B
while making a and A constant. Then, a change of DOF is
investigated by varying B while making a and A constant. As
discussed, the DOF is determined to be the minimum defocus amount
when the sizes of nine holes change by 10% of the size with the
best focus. FIGS. 11 and 12 show results of MEF and DOF,
respectively.
[0061] The result of MEF in FIG. 11 shows that the MEF becomes
small as the effective light-source parameter B is small. As
discussed, the smaller MEF is preferable. The result of DOF in FIG.
12 shows that the DOF becomes large as the effective light-source
parameter B is large. As discussed, the larger DOF is
preferable.
[0062] Influences of the effective light-source parameter a on the
MEF and DOF are investigated like a matrix by varying .sigma. with
various A and B. As an example, FIGS. 13 and 14 show MEF and DOF
with A fixed to 0.70, and B varied as 0.45, 0.5, 0.55 and 0.6. The
abscissa axis is .sigma., and the ordinate axis is MEF or DOF in
FIGS. 13 and 14. A color version of FIGS. 13 and 14 is attached to
this application for better understanding.
[0063] In general, large .sigma. includes more incident light
component that is effective to fine resolution and provide contrast
necessary for a fine pattern. The high contrast affects a resist
image by only an error amount in the mask pattern, whereas the low
contrast expands the error in the mask pattern and transfers it to
the resist. Therefore, it is expected that larger .sigma. provides
better contrast and is less influential on the MEF: The result in
FIG. 13 shows that larger a reduces MEF. MEF becomes minimum with
certain .sigma., A and B. Combinations of .sigma., A and B to
minimize the MEF have been investigated under 120 nm (with
k.sub.1=0.35) and it is found that MEF meets
3.00.ltoreq.MEF.ltoreq.3.15 when 0.85.ltoreq..sigma..ltoreq.0.9,
0.6.ltoreq.A.ltoreq.0.65, 0.45.ltoreq.B.ltoreq.0.55.
[0064] It is in general well-known that larger .alpha. easily
resolves a fine pattern, but disadvantageously reduces the DOF.
FIG. 14 appears to demonstrate this tendency even in the inventive
method. Smaller .sigma. expands the DOF, but deteriorates the MEF
and the resolution of a fine pattern near the resolution limit.
Therefore, the necessary DOF should be secured without
deteriorating the MEF and the resolution of a fine pattern.
Combinations of .sigma., A and B for small MEF and large DOF have
been found under 120 nm (with k.sub.1=0.35):
3.00.ltoreq.MEF.ltoreq.3.15 and 0.35.ltoreq.DOF.ltoreq.0.55, when
.sigma.=0.85, 0.6.ltoreq.A.ltoreq.0.65 and B=0.55.
[0065] The larger exposure dose tolerance is practically
preferable, because the exposure dose tolerance means that the
resolved contact-hole size does not change even with a slight error
in the exposure dose and permits an error of the exposure dose.
Therefore, constant resolving power and resolved hole size should
be secured within a certain exposure dose range. Accordingly, a
change of DOF is investigated when the exposure dose changes by
.+-.5%, and the exposure light-source parameters in the
illumination system are optimized so as to reduce the reduction
amount.
[0066] Initially, the DOF is investigated with the optimal exposure
dose, and a reduction of the DOF is investigated when the exposure
dose changes by +5% compared with the former. DOF is defined as the
minimum defocus amount value when the size of the nine holes
changes by 10% from the size at the best focus. FIG. 15 shows the
result. DOF reduces by about 5% in the holes of 120 nm when the
exposure does changes by .+-.5% even when the effective
light-source parameter values slightly change in the illumination
system. The smaller hole size would start dependency upon the
effective light-source parameter values. A color version of FIG. 15
is attached to the instant application for better
understanding.
[0067] Thus, combinations of effective light-source parameters have
been obtained which reduces MEF so that it is less affected by the
mask errors, maintains sufficient DOF, and enlarges exposure dose
tolerance so that even a slight error in the exposure dose may
provide the constant size.
[0068] A restriction condition will be discussed before
combinations of the optimal parameters of the effective light
source are discussed. The parameters A and B that define a size of
the light-shielding part should be smaller than a radius .sigma.
over the entire area of the effective light source. Since A is
defined as one larger than B, .sigma.>A>B should be met. A=B
is not included since the effective light-source distribution exits
only on the X-axis and Y-axis without diagonal distribution as
shown in FIG. 5. Without the diagonal distribution, a dummy
resolution tends to occur and it becomes difficult to obtain the
process tolerance. Similarly, the effective light-source
distribution exits only on the X-axis and Y-axis without diagonal
distribution when as B 2 is equal to or larger than .sigma. as
shown in FIG. 6. Therefore, B 2<.sigma. should be met.
[0069] Next follows optimal combinations of .sigma., A and B that
meet the above two conditions and depend upon the hole size (or
resolving power k.sub.1).
[0070] For 100 nm (with k.sub.1=0.29), A=0.75,
0.5.ltoreq.B.ltoreq.0.55, .sigma.=0.85
(0.85.ltoreq..sigma..ltoreq.0.9).
[0071] For 110 nm (with k.sub.1=0.32), A=0.70,
0.5.ltoreq.B.ltoreq.0.55, .sigma.=0.85
(0.80.ltoreq..sigma..ltoreq.0.9).
[0072] For 120 nm (with k.sub.1=0.35), A=0.65,
0.5.ltoreq.B.ltoreq.0.55, .GAMMA.=0.85
(0.80.ltoreq..sigma..ltoreq.0.9).
[0073] For 130 nm (with k.sub.1=0.38), A=0.65,
0.5.ltoreq.B.ltoreq.0.55, .sigma.=0.85
(0.80.ltoreq..sigma..ltoreq.0.9).
[0074] Therefore, a value of the effective light-source parameter A
is important for hole size to be resolved in the fine hole pattern
with k.sub.1 is 0.4 or less. B may be a constant value near 0.55. B
excessively close to A in A>B would decrease the diagonal
light-source area and reduce the exposure dose tolerance.
Therefore, a difference between A and B should be 0.1 or larger,
i.e., B.ltoreq.A-0.1. .sigma.=0.85 would balance the MEF and DOF,
and .sigma. is adjusted in the parenthesis range so that it is made
larger to reduce MEF and made smaller to improve DOF.
.sigma.excessively close to A would decrease the light-source area
on the X-axis and Y-axis and deteriorate the mask error
sensitivity. Therefore, a difference between .sigma. and A should
be 0.1 or larger, i.e., .sigma..gtoreq.A+0.1, so as not to prevent
the MEF from deteriorating.
[0075] The empirical rule based on this process tolerance is as
follows: A=A(k.sub.1)=-1.7k.sub.1+C1, 1.2.ltoreq.C1.ltoreq.1.3
0.5.ltoreq.B.ltoreq.0.55 and B.ltoreq.A-0.1
0.80.ltoreq..sigma..ltoreq.0.9 and .sigma..gtoreq.A+0.1 [0076]
.sigma. may be adjusted in this range so that it is made larger to
reduce MEF and made smaller to improve DOF. The optimal solution
that balances the MEF and DOF is A=A(k.sub.1)=-1.7k.sub.1+1.25, B
and .sigma. distribute at centers of B=0.55 and .sigma.=0.85
irrespective of the critical dimension under condition of
k.sub.1.ltoreq.0.4. The theoretically obtained best solution for
contrast provides A={(1/k.sub.1)/2-0.1}/2=1/(4k.sub.1)-0.05, but
this may be slightly corrected for process tolerance as
A=1/(4k.sub.1)-C2/(4k.sub.1).sup.2, where C2 is valid in a range of
0.07.ltoreq.C2.ltoreq.0.20. C2=0.12 provides a solution that
balances the MEF and DOF.
EXAMPLE
[0077] A description will be given of an exposure apparatus
according to the present invention with reference to FIG. 18. Here,
FIG. 18 is a schematic block diagram of the exposure apparatus. The
exposure apparatus includes, as shown in FIG. 18, an illumination
apparatus 100, a mask 200, a projection optical system 300, and a
wafer 400. The exposure apparatus of the instant embodiment is an
exposure apparatus that exposes a circuit pattern created on the
mask 200 onto the wafer 400 in a step-and-scan manner.
[0078] The illumination apparatus 100 illuminates the binary mask
200 that forms a contact-hole pattern, and includes a light source
section 110 and an illumination optical system 120. The light
source section 110 includes KrF excimer laser with a wavelength of
about 248 nm as a light source and a necessary beam shaping
system.
[0079] The illumination optical system 120 is an optical system to
illuminates the mask 200, and includes a condenser optical system
130, a fly-eye lens 140, an aperture stop 150, and a condenser lens
160 in the instant embodiment.
[0080] The condenser optical system 130 includes one or more
mirrors and lenses necessary for deflection, and maintains the
light that has passed them substantially parallel to any lens
element at the center and peripheral of the fly-eye lens 140. The
condenser optical system 130 includes an exposure-dose adjustment
part 132 that may change the exposure dose of the illumination
light to the binary mask 200 for each illumination. The
exposure-dose adjustment part 132 adjusts the exposure dose based
on contrast necessary for the desired contact holes on the mask 200
and/or wafer 400.
[0081] The fly-eye lens 140 makes uniform the illumination light to
the mask 200, and emits the light while converting an angular
distribution of the incident light into a positional distribution.
The aperture stop 150 is provided just after the exit surface of
the fly-eye lens 140, which has a fixed shape and diameter. This
aperture stop 150 has an aperture shape shown in FIG. 1 or 4 to
illuminate the mask 200, and thus restrains the exposure dose to
the dummy resolution pattern while enhancing the exposure dose to
the desired contact-hole pattern.
[0082] The aperture stop 150 is located at a position conjugate
with a pupil surface 320 in the projection optical system 300, and
the aperture shape of the aperture stop 150 corresponds to the
effective light source shape on the pupil surface 320 in the
projection optical system 300.
[0083] The binary mask 200 forms a pattern shown in FIG. 2 to
obtain the desired pattern with a hole diameter of 120 nm shown in
FIG. 3, and sets t=120 nm and d=90 nm for the hole diameter
converted into that on the wafer 400.
[0084] The projection optical system 300 images diffracted light
through the contact-hole pattern formed on the mask 200 onto the
wafer 400. 320 is the pupil surface in this projection optical
system 300. The projection optical system 300 of the instant
embodiment has an NA of 0.73. Photoresist is applied onto the wafer
400.
[0085] The exposure apparatus obtains a size of a desired hole by
reading out a barcode on the mask 200, and automatically sets an
optimal effective light source in the illumination optical system.
Alternatively, the effective light source in the illumination
system may be set by inputting effective light-source parameters
into the exposure apparatus. When the input value of the effective
light-source parameters offset from the optimal parameter values,
the exposure apparatus may output optimal parameter values with
warning on its console screen.
[0086] When the input value of the effective light-source parameter
falls within .sigma..ltoreq.A, A=B and B 2.gtoreq..sigma., an error
message emits so as not to enter the input value and prompt to
input the optimal parameter value.
[0087] The instant embodiment sets effective .sigma. of the
illumination light to 0.85, the lengths A and B in the
light-shielding part to 0.7 and 0.5. The exposure-dose adjustment
part 132 sets a light intensity ratio to 1:1 between the
illumination light that has an intensity distribution peak of the
light near the optical axis and the illumination light that has an
intensity distribution peak near at diagonals, adjusting the
exposure dose evenly.
[0088] The exposure apparatus exposes the binary mask 200 after
setting a wafer plate onto which an anti-reflection film AR3 (60
nm) and photoresist TDK-DP746HC with a thickness of 350 nm are
applied. Then, the post exposure bake ("PEB") continues for 90
seconds at temperature of 140.degree. C., followed by the
development for 60 seconds at 23.degree. C. using developer of
NMD-3. The exposure sets the exposure dose every 5 mJ/cm.sup.2 from
250 mJ/cm.sup.2 to 400 mJ/cm.sup.2 and varies it in a focus
direction.
[0089] FIG. 16 shows an exposure result with the exposure dose of
340 mJ/cm.sup.2. An exposure result with other exposure dose is
omitted. The exposure result changes a focus position at a pitch of
0.05 .mu.m with a defocus amount of -0.25 .mu.m to 0.30 .mu.m in a
lateral direction. Referring to FIG. 16, the exposure result at
0.30 .mu.m shows that part of holes does not perforate through the
resist while the resist shows successful perforation with other
defocus amounts of -0.25 .mu.m to 0.25 .mu.m without hole size
reduction. The hole size deviates within .+-.10% of a certain size
with the defocus amount from 0.15 .mu.m to 0.20 .mu.m. In other
words, each hole is dimensioned from 108 nm to 132 nm for a certain
size of 120 nm. DOF of 0.35 .mu.m is obtained.
[0090] FIG. 17 shows a process window when the exposure dose and
defocus amount change, in which the abscissa axis indicates a
change of focus and the ordinate axis indicates a change of
exposure dose. FIG. 17 uses .smallcircle. to show a successful
perforation of the hole down to the wafer substrate without hole
size reduction, and .circle-solid. to show that an observed value
of the hole size is within .+-.10% of the certain size. Strict
criteria applied because .smallcircle. is not given when the hole
perforates but with hole size reduction and .circle-solid. is not
given when even one hole among the nine holes deviates from the
predetermined range by 1 nm. Nevertheless, the exposure dose
tolerance of 20 mJ/cm.sup.2 provides about 0.3 DOF.
[0091] The sufficient process tolerance was similarly obtained for
a mask pattern with t=120 nm and d=100 nm converted into those on
the wafer for the desired size of 120 nm. This case used smaller
optimal exposure dose and thus showed a slightly advantageous
result in view of throughput.
[0092] Referring now to FIGS. 19 and 20, a description will be
given of an embodiment of a device fabrication method using the
above mentioned exposure apparatus. FIG. 19 is a flowchart for
explaining how to fabricate devices (i.e., semiconductor chips such
as IC and LSI, LCDs, CCDs, and the like). Here, a description will
be given of the fabrication of a semiconductor chip as an example.
Step 1 (circuit design) designs a semiconductor device circuit.
Step 2 (mask fabrication) forms a mask having a designed circuit
pattern. Step 3 (wafer making) manufactures a wafer using materials
such as silicon. Step 4 (wafer process), which is also referred to
as a pretreatment, forms actual circuitry on the wafer through
lithography using the mask and wafer. Step 5 (assembly), which is
also referred to as a post-treatment, forms into a semiconductor
chip the wafer formed in Step 4 and includes an assembly step
(e.g., dicing, bonding), a packaging step (chip sealing), and the
like. Step 6 (inspection) performs various tests for the
semiconductor device made in Step 5, such as a validity test and a
durability test. Through these steps, a semiconductor device is
finished and shipped (Step 7).
[0093] FIG. 20 is a detailed flowchart of the wafer process in Step
4. Step 11 (oxidation) oxidizes the wafer's surface. Step 12 (CVD)
forms an insulating film on the wafer's surface. Step 13 (electrode
formation) forms electrodes on the wafer by vapor disposition and
the like. Step 14 (ion implantation) implants ion into the wafer.
Step 15 (resist process) applies a photosensitive material onto the
wafer. Step 16 (exposure) uses the exposure apparatus 300 to expose
a circuit pattern on the mask onto the wafer. Step 17 (development)
develops the exposed wafer. Step 18 (etching) etches parts other
than a developed resist image. Step 19 (resist stripping) removes
disused resist after etching. These steps are repeated, and
multi-layer circuit patterns are formed on the wafer. Use of the
fabrication method in this embodiment helps fabricate
higher-quality devices than ever. Thus, the device fabrication
method using the exposure apparatus 1 and the resultant device
constitute one aspect of the present invention.
[0094] Thus, the present invention may provide an exposure
apparatus that uses a usual exposure apparatus with KrF excimer
laser with a wavelength of 248 nm and NA of 0.73 to realize
resolving power k.sub.1=0.35 or smaller with practical DOF and
resolve fine opening of 120 nm or smaller.
* * * * *