One of the key methods targeted for continuing the resolution scaling in new device technology nodes is the trend towards using curvilinear mask patterns. With recent advances in multi-beam mask patterning and large-scale adoption of ILT mask data correction, curvilinear (and all-angle) mask patterns are considered today as a mainstream technology option. Curvilinear mask patterns provide improved wafer resolution and OPC/ILT mask correction control with reduced mask manufacturing issues related to tight corners and line-ends. However, OPC, ILT, LRC and other full-chip simulation-based mask synthesis methods also require more accurate electromagnetic (i.e., M3D) simulation for new technology nodes. Prior full-chip electromagnetic simulation methods have often assumed that mask patterns are restricted to Manhattan geometries or utilize limited angles. Therefore, there is a general industry need for improved electromagnetic full-chip simulation methods for curvilinear mask patterns. This paper will present a new electromagnetic full-chip simulation method for curvilinear mask patterns that will improve the accuracy of mask synthesis methods at upcoming technology nodes. This method can provide both accuracy and speed benefits on mask synthesis with curvilinear mask patterns for both DUV and EUV lithography. The method utilizes an enhanced physics-based treatment of electromagnetic mask scattering both tuned and verified by rigorous electromagnetic Maxwell’s equation solvers.
To successfully transfer design patterns to wafer, it is essential to calibrate different types of models to describe the optical, physical, and chemical effects in chip manufacturing process. In recent years, there have also been active investigations of machine learning (ML) models to capture various aspects of semiconductor processes. As it is well known, model training time and model accuracy are heavily influenced by the input data. It is becoming increasingly important to provide highly efficient methods to automatically generate effective pattern samples from full chip designs. A straightforward approach, simple random sampling, can be highly efficient to generate effective samples for a homogeneous population. However, real world chip layouts are characterized by geometrical and lithographical feature distributions that vary significantly across the full chip design space. The complexity of the problem necessitates the adoption of a comprehensive set of approaches for sampling as well as flexibility in customizing the sampling strategy for various applications. In this paper, we investigate automatic layout sampling to optimize the coverage and diversity of patterns given the need for minimizing training sample size or other constraints, and therefore adopting various unsupervised learning techniques. The flow scales very well with computation resources to efficiently process full chip layouts. A simple, standard interface is provided for typical usage, but flexible programming APIs are available to customize the sampling strategy for advanced applications. Results demonstrate that the samples generated by this flow have increased diversity, which leads to significantly reduced model training time with comparable or increased model accuracy.
The first high-NA EUVL scanner will have an 0.55 NA and will use anamorphic magnification. Therefore, the standard 10×13 cm lithography mask will be imaged into a 2.6×1.65 cm rectangle on the wafer due to the increased reduction factor of the lens’ vertical direction. Layers exposed on high-NA anamorphic scanners will require two stitched halffields to achieve the equivalent exposure area of previous-generation scanners. Stitching strategies will depend on the product type being manufactured. For chips with a large die area, it will be necessary to stitch fields across the die. For smaller chips, it may be advantageous to use three stitched exposures depending on the die size. In any case, the stray light from neighboring fields and black border proximity effects cause challenges for robust manufacturing. Some recent studies have shown that the CD may vary significantly as a function of the proximity to the black border edge due to multilayer stresses. In addition, stitching through a die has increased optical proximity effects which will need to be corrected to achieve the desired wafer CD. In this paper we examine the effects relevant to designing a stitched process, quantify manufacturing tolerances, and show how these effects can be corrected with EDA. More specifically, we examine the optical and mechanical properties of the multi-layer black border etch and optimization of sub-resolution gratings to reduce reflectivity with phase shifting absorber materials. Ultimately, we will show that for a well designed stitch, the effects of stitching can be corrected without impact to process window.
The lithography industry has historically striven to improve resolution by reducing wavelength and increasing the lens’ numerical aperture (NA). The introduction of 0.33 NA extreme ultraviolet (EUV) lithography into high-volume manufacturing (HVM) represents the largest jump in resolution ever achieved by the industry. However, even this resolution is not sufficient for the patterns required for beyond the 2 nm logic technology node. This is due to low contrast and the diffraction limit of current EUVL scanners for the mask patterns required for these nodes. Instead, the resolution must be improved by increasing the NA. This will also increase the contrast of patterns which had insufficient contrast at 0.33 NA, which will in turn improve LCDU and defectivity. This change is not without its challenges though. Increasing the NA from 0.33 to 0.55 will cause a significant reduction in depth of focus. In addition, stronger mask 3D effects can cause pattern dependent shifts in best focus. As a result, the common overlapping process window of several critical patterns can become strongly diminished. The use of anamorphic optics will require two separate half-field exposures to obtain the equivalent of a single full-field exposure on current EUV and DUV scanners. For some chip sizes, this will require stitching two half-fields together to pattern the full chip area. In previous technology nodes, the process window could be improved using SMO and SRAFs. In addition, over the last five years, the industry has put significant effort into studying alternative absorbing materials. These materials can significantly reduce the mask 3D effects by reducing the thickness of the absorber. The use of alternative absorbers alone will not be sufficient for improving the overlapping process window. Instead, several techniques must be simultaneously utilized in order to ensure sufficient overall process window. Optimization of overlapping process windows is critical for successful insertion of high-NA EUVL into HVM. In this paper we analyze how the process window of critical patterns can be optimized by using different optimizations. We will show for realistic mask designs how process window can be improved in different process steps. Double exposure from half-field stitching will also be included in the process evaluation. We use both rigorous and compact modeling in a complimentary fashion for overall process optimization analysis. All techniques presented in this paper accurately model the anamorphic, centrally obscured optics of the upcoming next-generation high-NA scanners.
Directed self-assembly (DSA) of block copolymers offers opportunities for resolution enhancement of existing patterning by pitch splitting, contact hole (CH) shrinks or, improvement of pattern profile or patterning window.1-2 By co-optimization of guiding pattern geometry, guiding pattern profile, block copolymer formulation, pattern transfer steps, the after-etch DSA patterns meet target pitch ratio. This DSA assessment shows combination of DSA and single iArF-patterning has potential to meet the specific CD dimension and pitch requirement of a conventional patterns that requires double-patterning.
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