Full flow focus exposure matrix analysis and electrical testing for new product mask evaluation
First Claim
1. A method for new product mask evaluation, comprising:
- reticle scanning;
printability simulating based, at least in part, on the reticle scanning;
printing one or more focus exposure matrices on a full flow production wafer;
defect scanning;
flat wafer monitoring;
critical dimension measuring;
full flow production wafer focus exposure matrix monitoring;
end of line electrical testing; and
defect detecting.
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Abstract
A method for new product mask evaluation is provided. Focus exposure matrices are printed at one or more layers (e.g., active gate) on full flow production wafers. The focus exposure matrices are then analyzed to produce data that facilitates detecting printed defects. The full flow production wafers are also subjected to end of line electrical testing to determine bit level errors. Print defects can be correlated with bit level errors to increase confidence in detected defects. The method includes a hierarchy of testing layers, each of which produce data that can be employed in detecting defects in a reticle and/or producing a yield analysis. The method involves scanning a reticle upon which the new product mask is etched and performing a printability simulation to determine what affect, if any, detected reticle defects will have on printing defects on a wafer. After the reticle is scanned, full flow production wafers printed from the pattern on the reticle can be scanned for defects, as can resist-on-silicon flat test wafers, where a higher signal to noise ratio facilitates detecting defects that may otherwise not be detected. The reticle scanning can include critical dimension measuring by scanning electron microscopy means and/or scatterometry means.
113 Citations
27 Claims
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1. A method for new product mask evaluation, comprising:
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reticle scanning;
printability simulating based, at least in part, on the reticle scanning;
printing one or more focus exposure matrices on a full flow production wafer;
defect scanning;
flat wafer monitoring;
critical dimension measuring;
full flow production wafer focus exposure matrix monitoring;
end of line electrical testing; and
defect detecting. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
generating an actual yield data; and
correlating the actual yield data with a prediction yield data.
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12. The method of claim 1, wherein the focus exposure matrix is formed from a plurality of patterns created with varying resist exposure dosages and stepper focuses.
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13. A data packet adapted to be transmitted between two or more processes, the data packet containing defect analysis information and product yield information produced by a method for new product mask evaluation, comprising:
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reticle scanning;
printability simulating based, at least in part, on the reticle scanning;
defect scanning;
printing one or more focus exposure matrices on a full flow production wafer;
flat wafer track monitoring;
critical dimension measuring;
full flow product focus exposure matrix monitoring;
end of line electrical testing;
defect detecting; and
product yield analyzing.
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14. A system for new product mask evaluation, comprising:
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a reticle scanner operably coupled to a defect analyzer;
a printability simulator operably coupled to the defect analyzer;
a defect scanner operably coupled to the defect analyzer;
a flat wafer monitor operably coupled to the defect analyzer;
a critical dimension monitor operably coupled to the defect analyzer;
a full flow product focus exposure matrix monitor operably coupled to the defect analyzer; and
an end of line electrical tester operably coupled to the defect analyzer. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
generate an actual yield data; and
correlate the actual yield data with a prediction yield data.
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26. A data packet adapted to be transmitted between two or more processes, the data packet containing defect detection information and product yield information produced by a system comprising:
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a defect analyzer;
a reticle scanner operably coupled to the defect analyzer;
a printability simulator operably coupled to the defect analyzer;
a defect scanner operably coupled to the defect analyzer;
a flat wafer monitor operably coupled to the defect analyzer;
a critical dimension monitor operably coupled to the defect analyzer;
a full flow product focus exposure matrix monitor operably coupled to the defect analyzer;
an end of line electrical tester operably coupled to the defect analyzer; and
a yield predictor operably coupled to the defect analyzer.
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27. A method for new product mask evaluation, comprising:
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processing one or more focus exposure matrices (FEMs) onto a full flow product wafer;
analyzing the FEMs;
performing end of line electrical testing of one or more integrated circuits produced from the full flow product wafer upon which the one or more FEMs were processed; and
performing a yield analysis in connection with determining an overall yield based, at least in part, on data associated with analyzing the FEMs and data associated with the end of line electrical testing of the one or more integrated circuits.
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Specification