Exposure focus leveling method using region-differentiated focus scan patterns
First Claim
1. A method of operating a lithographic exposure tool, comprising:
- forming semiconductor dies arranged in a plurality of rows and columns in an array on a substrate, wherein the array has a first periodicity along a first horizontal direction and a second periodicity along a second horizontal direction within a horizontal plane that is parallel to a top surface of the substrate, and each semiconductor die includes a first image region and a second image region having a different pattern of structural components than the first image region;
applying a photoresist layer over the semiconductor dies;
loading the substrate on a stage in the lithographic exposure tool;
generating a first map of first optimal focus distances along first scan paths that extend along the first horizontal direction and over the first image regions of the semiconductor dies on the substrate, wherein the first scan paths do not cross any of the second image regions of the semiconductor dies;
generating a second map of second optimal focus distances along second scan paths that extend along the first horizontal direction and over the second image regions of the semiconductor dies on the substrate, wherein the second scan paths do not cross any of the first image regions of the semiconductor dies; and
leveling the substrate with respect to an optics system of the lithographic exposure tool.
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Abstract
Pattern-dependent random deviations in measurement of optimal focus distances can be minimized by separating scan paths into multiple types of scan paths that scan only a respective predetermined image region in semiconductor dies. A substrate including in-process semiconductor dies is coated with a photoresist layer, and is located onto a stage in a lithographic exposure tool. Maps of optimal focus distances are generated by performing optimal focus distance scans that cover a respective subset of image regions having distinct image patterns. The substrate can be leveled with respect to an optics system of the lithographic exposure tool employing a weighted average of multiple maps of optimal focus distances. Once the substrate is leveled on the stage, a lithographic exposure process can be performed with enhanced uniformity in the focus distances across the in-process semiconductor dies.
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Citations
20 Claims
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1. A method of operating a lithographic exposure tool, comprising:
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forming semiconductor dies arranged in a plurality of rows and columns in an array on a substrate, wherein the array has a first periodicity along a first horizontal direction and a second periodicity along a second horizontal direction within a horizontal plane that is parallel to a top surface of the substrate, and each semiconductor die includes a first image region and a second image region having a different pattern of structural components than the first image region; applying a photoresist layer over the semiconductor dies; loading the substrate on a stage in the lithographic exposure tool; generating a first map of first optimal focus distances along first scan paths that extend along the first horizontal direction and over the first image regions of the semiconductor dies on the substrate, wherein the first scan paths do not cross any of the second image regions of the semiconductor dies; generating a second map of second optimal focus distances along second scan paths that extend along the first horizontal direction and over the second image regions of the semiconductor dies on the substrate, wherein the second scan paths do not cross any of the first image regions of the semiconductor dies; and leveling the substrate with respect to an optics system of the lithographic exposure tool. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method of operating a lithographic exposure tool, comprising:
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forming semiconductor dies arranged in a plurality of rows and columns in an array on a substrate, wherein the array has a first periodicity along a first horizontal direction and a second periodicity along a second horizontal direction within a horizontal plane that is parallel to a top surface of the substrate, and each semiconductor die includes a first image region comprising a NAND memory plane, at least one second image region comprising a NAND word line contact region which comprises a pattern of stepped surfaces of word lines that continuously extend into an area of the first image region along the second horizontal direction, and a third image region which comprises sense amplifier circuitry in a peripheral device region that is electrically connected to bit lines that laterally extend into the area of the first image region along the first horizontal direction applying a photoresist layer over the semiconductor dies; loading the substrate on a stage in the lithographic exposure tool; generating a first map of first optimal focus distances along first scan paths that extend along the first horizontal direction and over the first and the third image regions of the semiconductor dies on the substrate, wherein the first scan paths do not cross any of the second image regions of the semiconductor dies; generating a second map of second optimal focus distances along second scan paths that extend along the first horizontal direction and over the second image regions of the semiconductor dies on the substrate, wherein the second scan paths do not cross any of the first and third image regions of the semiconductor dies; and leveling the substrate with respect to an optics system of the lithographic exposure tool. - View Dependent Claims (20)
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Specification