WO2001035718A2 - System and method for product yield prediction - Google Patents
System and method for product yield prediction Download PDFInfo
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- WO2001035718A2 WO2001035718A2 PCT/US2000/031665 US0031665W WO0135718A2 WO 2001035718 A2 WO2001035718 A2 WO 2001035718A2 US 0031665 W US0031665 W US 0031665W WO 0135718 A2 WO0135718 A2 WO 0135718A2
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B15/00—Systems controlled by a computer
- G05B15/02—Systems controlled by a computer electric
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/30—Circuit design
- G06F30/39—Circuit design at the physical level
- G06F30/398—Design verification or optimisation, e.g. using design rule check [DRC], layout versus schematics [LVS] or finite element methods [FEM]
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L22/00—Testing or measuring during manufacture or treatment; Reliability measurements, i.e. testing of parts without further processing to modify the parts as such; Structural arrangements therefor
- H01L22/20—Sequence of activities consisting of a plurality of measurements, corrections, marking or sorting steps
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L22/00—Testing or measuring during manufacture or treatment; Reliability measurements, i.e. testing of parts without further processing to modify the parts as such; Structural arrangements therefor
- H01L22/30—Structural arrangements specially adapted for testing or measuring during manufacture or treatment, or specially adapted for reliability measurements
- H01L22/34—Circuits for electrically characterising or monitoring manufacturing processes, e. g. whole test die, wafers filled with test structures, on-board-devices incorporated on each die, process control monitors or pad structures thereof, devices in scribe line
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
Definitions
- the present invention pertains to fabrication of integrated circuits and more particularly to systems and methods for improving fabrication yields.
- the fabrication of integrated circuits is an extremely complex process that may involve hundreds of individual operations.
- the process includes the diffusion of precisely predetermined amounts of dopant material into precisely predetermined areas of a silicon wafer to produce active devices such as transistors. This is typically done by forming a layer of silicon dioxide on the wafer, then utilizing a photomask and photoresist to define a pattern of areas into which diffusion is to occur through a silicon dioxide mask. Openings are then etched through the silicon dioxide layer to define the pattern of precisely sized and located openings through which diffusion will take place. After a predetermined number of such diffusion operations have been carried out to produce the desired number of transistors in the wafer, they are interconnected as required by interconnection lines.
- interconnection lines are typically formed by deposition of an electrically conductive material which is defined into the desired interconnect pattern by a photomask, photoresist and etching process.
- a typical completed integrated circuit may have millions of transistors contained with a 0.1 inch by 0.1 inch silicon chip and interconnects of submicron dimensions.
- the manufacturing processes be carried out with utmost precision and in a way that minimizes defects.
- the electrical characteristics of the circuits must be kept within carefully controlled limits, which implies a high degree of control over the myriad of operations and fabrication processes.
- the presence of contaminants such as dust, minute scratches and other imperfections in the patterns on the photomasks can produce defective patterns on the semiconductor wafers, resulting in defective integrated circuits. Further, defects can be introduced in the circuits during the diffusion operations themselves. Defective circuits may be identified both by visual inspection under high magnification and by electrical tests. Once defective integrated circuits have been identified, it is desired to take steps to decrease the number of defective integrated circuits produced in the manufacturing process, thus increasing the yield of the integrated circuits meeting specifications.
- a system and method for predicting yield of integrated circuits includes at least one type of characterization vehicle which incorporates at least one feature which is representative of at least one type of feature to be incorporated in the final integrated circuit product.
- the characterization vehicle is subjected to at least one of the process operations making up the fabrication cycle to be used in fabricating the integrated circuit product in order to produce a yield model.
- the yield model embodies a layout as defined by the characterization vehicle and preferably includes features which facilitate the gathering of electrical test data and testing of prototype sections at operating speeds.
- An extraction engine extracts predetermined layout attributes from a proposed product layout. Operating on the yield model, the extraction engine produces yield predictions as a function of layout attributes and broken down by layers or steps in the fabrication process. These yield predictions are then used to determine which areas in the fabrication process require the most improvement.
- FIGURE 1 is a block diagram depicting the steps performed by a preferred embodiment of the system of the present invention.
- FIGURE 2 is a block diagram depicting additional steps performed by the system of the present invention to effect a feedback loop.
- FIGURE 3 is an image of an illustrative short flow mask comprising a single lithographic layer.
- FIGURE 4 depicts pad frames on an exemplary metal short flow chip.
- FIGURE 5 depicts pads within each pad frame depicted in FIGURE 4.
- FIGURE 6 depicts two types of pad frame structures which contain van der Pauw structures.
- FIGURE 7 depicts locations, on the exemplar)' chip, of the pad frames containing the van der Pauw structures.
- FIGURE 8 depicts an exemplary van der Pauw structure.
- FIGURE 9 depicts exemplary locations of nest defect size distribution structures on an exemplary metal short flow chip.
- FIGURE 10 depicts an exemplary nest defect size distribution structure.
- FIGURE 11 depicts an exemplary Kelvin critical dimension structure.
- FIGURE 12 depicts exemplary locations of Kelvin structures on an exemplary metal short flow chip.
- FIGURE 13 depicts exemplary locations of snakes and combs on an exemplar ⁇ ' metal short flow chip.
- FIGURE 14 depicts exemplar ⁇ ' snake and comb structures used in an exemplar ⁇ ' metal short flow chip.
- FIGURE 15 depicts examples of variations of border structures used in an exemplary metal short flow chip.
- FIGURE 16 depicts exemplary locations of border structures on an exemplary metal short flow chip.
- FIGURE 17 depicts exemplary locations of scanning electron microscope structures on an exemplary metal short flow chip.
- FIGURE 18 depicts an exemplary test structure illustrating a shortable area.
- FIGURE 19 depicts an exemplary test pattern for examining the yield of T-shaped endings at the ends of lines.
- FIGURE 20 depicts an exemplary nest structure for extracting defect size distributions.
- FIGURE 21 depicts a plot for determining the rate at which defects decay over size.
- FIGURE 22(a), 22(b) and 22(c) depict, respectively, linewidth, linespace and pattern density distributions for a metal- 1 layer of a sample product layout.
- the system 10 utilizes at least one type of characterization vehicle 12.
- the characterization vehicle 12 preferably is in the form of software containing information required to build an integrated circuit structure which incorporates at least one specific feature representative of at least one type of feature to be incorporated into the final product.
- the characterization vehicle 12 might define a short flow test vehicle of a single lithographic layer for probing the health and manufacturability of the metal interconnection module of the process flow under consideration.
- the structures need to be large enough and similar enough to the actual product or type of products running in the fabrication process to enable a reliable capture or fingerprint of the various maladies that are likely to affect the product during the manufacturing. More specific examples and descriptions of short flows and the structures embodied in them are described below.
- Short flow is defined as encompassing only a specific subset of the total number of process steps in the integrated circuit fabrication cycle. For example, while the total fabrication cycle might contain up to 450 or more process steps, a characterization vehicle such as one designed to investigate manufacturability of a single interconnection layer would only need to include a small number, for example 10 to 25 process steps, since active devices and multiple interconnection layers are not required to obtain a yield model or allow accurate diagnosis of the maladies afflicting these steps associated with a single interconnection layer in the process flows.
- the characterization vehicle 12 defines features which match one or more attributes of the proposed product layout.
- the characterization vehicle 12 might define a short flow test vehicle having a partial layout which includes features which are representative of the proposed product layout (e.g. examples of line size, spacing and periodicity; line bends and runs; etc.) in order to determine the maladies likely afflicting those specific design types and causing yield loss.
- the characterization vehicle 12 might also define one or more active regions and neighboring features of the proposed design in order to explore impact of layout neighborhood on device performance and process parameters; model device parameters as a function of layout attributes; and determine which device correlate best with product performance. Furthermore, by constructing and analyzing a sufficient number of short flow vehicles such that the range of all possible or a major subset of all the modular components of the entire process is exercised, a full evaluation of many if not all of the yield problems which will afflict the specific product manufactured can be uncovered, modeled, and/or diagnosed.
- the characterization vehicle is designed to produce yield models 16 which can be used for accurate yield prediction.
- yield models 16 can be used for purposes including, but not limited to, product planning, prioritizing yield improvement activities across the entire process, and modifying the original design of the product itself to make it more manufacturable.
- the majority of the test structures in the characterization vehicle 12 contemplated in the invention are designed for electrical testing. To this end, the reliability of detecting faults and defects in the modules evaluated by each characterization vehicle is very high. Inspection equipment cannot deliver or promise this high degree of reliability. Furthermore, the speed and volume of data collection is very fast and large respectively since electrical testing is fast and cheap. In this way, statistically valid diagnosis and/or yield models can be realized.
- the characterization vehicle 12 is preferably in the form of a GDS 2 layout on a tape or disc which is then used to produce a reticle set.
- the reticle set is used during the selected portions of the fabrication cycle 14 to produce the yield model 16.
- the yield model 16 is preferably constructed from data measured from at least a portion of a wafer which has undergone the selected fabrication process steps using the reticle set defined by the characterization vehicle 12.
- the yield model 16 not only embodies the layout as defined by the characterization vehicle, it also includes artifacts introduced by the fabrication process operations themselves.
- the yield model 16 may also include prototype architecture and layout patterns as well as features which facilitate the gathering of electrical test data and testing prototype sections at operating speeds which enhances the accuracy and reliability of yield predictions.
- An extraction engine 18 is a tool for extracting layout attributes from a proposed product layout 20 and plugging this information into the yield model 16 to obtain a product yield prediction 22.
- layout attributes might include, for example, via redundancy, critical area, net length distribution, and line width/space distribution. Then, given layout attributes from the proposed product layout 20 and data from yield models 16 which have been fabricated based upon information from the characterization vehicles 12, product yield 22 is predicted.
- the predictable product yield obtainable can be that associated with each defined attribute, functional block, or layer, or the resultant yield prediction for the entire product layout.
- FIG. 2 there is shown a block diagram of the system for predicting integrated circuit yields 10 in accordance with the present invention additionally comprising a feedback loop, generally designated 24, for extracting design attributes 26 from product layout 20 by means of extraction engine 28.
- the characterization vehicle 12 is developed using attributes of the product layout 20.
- attributes of the product layout are extracted, making sure that the range of attributes are spanned in the characterization vehicle 12.
- the product layout is analyzed to determine line space distribution, width distribution, density distribution, the number of island patterns, in effect developing a subset of the entire set of design rules of the fabrication process, which subset is applicable to the particular product layout under consideration.
- the product layout analysis would determine the most common pattern, the second most common pattern, and so forth. These would be extracted by the extraction engine 28 yielding design attributes 26 encompassing all of these patterns for inclusion into the characterization vehicle 12.
- the characterization vehicle would include the entire range of 10% to 50% for the first metal.
- One type of characterization vehicle is a metal short flow characterization vehicle. The purpose of the metal short flow characterization vehicle is to quantify the printability and manufacturability of a single interconnect layer.
- metal short flow is run very early in the process since metal yield is crucial for high product yield, is often very difficult to obtain, and consists of only a few independent processing steps.
- Conducting short flow experiments using a metal short flow mask enables experiments and analysis to be carried out in rapid succession to eliminate or minimize any systematic yield or random defect yield issue that is detected without having to wait for complete flow runs to finish.
- FIG. 3 there is shown an image of a typical and illustrative metal short flow mask, generally designated 30, which consists of a single lithographic layer.
- the mask 30 is used to define a single metal layer on a chip, and the exemplary chip 32 depicted in Figure 3 is as large as the stepper can accomodate which is, in this example, approximately 22 mm x 22 mm in size. It is divided into four quadrants, 42, 4, 46 and 48 as shown in Figure 4, each containing one or more of six basic structures: (i) Kelvin metal critical dimension structures; (ii) snake and comb structures; (iii) nest defect size distribution structures; (iv) van der Pauw structures; (v)
- Figure 3 also depicts the location of pad frames 34 on the chip.
- pad frames 34 there are 131 pad frames on the chip, with each pad frame 34 comprising thirty-two pads as shown in Figure 5.
- the pads within each pad frame 34 provide electrical connection points which are contacted by external test equipment as required by a test program to be described later.
- the van der Pauw test structures 82 used in this chip are four terminal square structures which take advantage of the symmetry of the structure for direct determination of the sheet resistance. Accurate determination of sheet resistance is a requirement for measurement of linewidth variation.
- the van der Pauw structures 82 are arranged in two different frame types: mixed 62 (see Figure 6A) and VDP 1 64 (see Figure 6 B).
- Figure 7 depicts the location of the pad frames 72 containing the van der Pauw structures in the exemplary metal short flow chip described herein. In this exemplar ⁇ ' chip, the van der Pauw structures occupy less than 1% of the chip area.
- the line width (LW) and the LW tap are the parameters that are varied. Table I shows the variations in the van der Pauw structures in the exemplary metal short flow chip described herein.
- the nest defect size distribution structures are arrays of nested continuous lines designed for opens and shorts detection and for the extraction of defect size distribution.
- Line width and space between the line are the parameters that are varied to facilitate the extraction of defect size distribution.
- these structures occupy 50% of the chip area at locations 92 and 94 shown in Figure 9 and have fourteen variants in a total of ten cells 96.
- the amount of area these structures can occupy needs to be large enough to accurately detect less than 0.25 defects/cm 2 for one wafer.
- the number of variants typically include the design rule (DR), slightly below DR, slightly above DR and substantially above DR. Therefore, for example, if DR is 1.0 ⁇ m for line spacing, the plots might be for 0.9, 1.1 , 1.3 and 2.5 as shown in Table II. TABLE II
- Each cell is split into six sub-cells to reduce the line resistance to reasonable levels (less than 250 k ⁇ ) and to minimize the incidence of multiple defects per cell.
- An exemplary nest defect size distribution structure itself, generaly designated 1002, is depicted in Figure 10.
- the nest defect size distribution structures are designed such that the line width (LW) is equal to the spacing (S) between the lines to simplify subsequent analysis of data.
- the Kelvin metal critical dimension (CD) structures are made up of a continuous straight line with terminal connections at each end. These structures allow for precise line resistance measurements which, in conjunction with the sheet resistance determined from the van der Pauw structures, allow for the determination of Kelvin line width. These structures are designed primarily to determine the variation in the electrical critical dimension.
- An exemplar ⁇ ' Kelvin critical dimension structure, generally designated 110, is depicted in Figure 11.
- the parameters varied for the local neighborhood are the number 112, line width 114 and space 116 of the lines.
- the global environment 118 around the Kelvin structures is also varied, primarily to study etch related effects on the electrical critical dimension (see Figure 11). Parameters varied for global neighborhood are the density and area.
- the global neighborhood structures can also serve other electrical measurement needs. For example, the yield of these structures can be measured so that not only metal critical dimension as a function of environment is obtained, but also yield as a function of environment.
- Figure 12 depicts the location of Kelvin structures 122 in the metal short flow chip described herein. These locations are chosen to cover available area. Tables III through IX describe the variations in the Kelvin structures used in the metal short flow chip described herein. These values were chosen as to cover the space identified in Figure 22(a) through 22(b). For example, the pattern density is centered around 45% and the line width and spaces are in the range of 1.0 to 3.3 ⁇ m since this is where most of an exemplary product layout is centered.
- the snake, comb and snake & comb structures are designed primarily for the detection of shorts and opens across a wide variety of patterns.
- Snakes are used primarily for the detection of opens and can also be used for monitoring resistance variation.
- Combs are used for monitoring shorts.
- Shorts and opens are fundamental yield loss mechanisms and both need to be minimized to obtain high product yield.
- Figure 13 shows the location of snakes and combs 1302 in the metal short flow chip described herein.
- Quadrant one 1304 also contains snakes 1402 and combs 1404 nested within the Kelvin structures asshown, for example in Figure 14.
- Line width (LW) and space (S), see Figure 14 are the parameters varied on these structures to study their impact on shorts and opens.
- Tables X through XIII describe the variations of snake and comb structures used in the metal short flow chip described herein. Again, the parameters were chosen such that the space covered in line width, line space, and density is similar to that seen in the example product layout, as shown in Figure 22(a) through 22(c).
- Border and fringe structures are designed to study the impact of optical proximity correction (OPC) structures on shorts. These optical proximity corrections are usually added to improve via yields. However, it is necessary to check metal short yield with and without these borders to ensure that there is no detrimental impact to short yield. Borders 1502 are placed both at the end of the comb lines and in the interior of comb structures, generally designated 1504, as shown in Figure 15. Figure 16 shows the location of border structures, generally designated 1602, in the metal short flow chip described herein.
- OPC optical proximity correction
- SEM Scanning electron microscopy
- the extraction engine 18 has two main purposes: (1) it is used in determining the range of levels (e.g. linewidth, linespace, density) to use when designing a characterization vehicle. (2) It is used to extract the attributes of a product layout which are then subsequently used in the yield models to predict yield. (1) has already been described above with reference to how the line width, space and density of the snake, comb and Kelvin structures were chosen in the example characterization vehicle. Thus, most of the following discussion focuses on (2).
- levels e.g. linewidth, linespace, density
- the characterization vehicle drives which attributes to extract. The process consists of:
- the yield model 16 is preferably constructed from data measured from at least a portion of a wafer which has undergone the selected fabrication process steps using the reticle set defined by the characterization vehicle 12.
- the yield is modeled as a product of random and systematic components:
- AREA BASED MODELS The area based model can be written as:
- Y 0 (q) is the yield of a structure with design factor q from the characterization vehicle.
- a 0 (q) is the shortable area of this structure and A(q) is the shortable area of all instances of type q on the product layout.
- Y r (q) is the predicted yield of this structure assuming random defects were the only yield loss mechanism. The procedure for calculating this quantity is described below in connection with random yield modeling. The definition of shortable area is best illustrated with the example shown in Figure 18. This type of test structure can be used to determine if the fab is capable of yielding wide lines that have a bend with a spacing of s.
- a short is measured by applying a voltage between terminal (1) and (2) and measuring the current flowing from terminal (1) to (2). If this current is larger than a specified threshold (usually 1-lOOnA), a short is detected.
- the shortable area is defined to be the area where if a bridging occurs, a short will be measured. In the example of Figure 18, the shortable area is approximately x*s).
- the A(q) term is the shortable area of all occurrences of the exact or nearly exact patten (i.e. a large line with a spacing of s and a bend of 45 degrees) shown in Figure 18 in a product layout.
- the Yr(q) term is extracted by predicting the random yield limit of this particular structure using the critical area method described below.
- Ni(q) is the number of times the unit cell pattern or very similar unit cell pattern to the test pattern on the characterization vehicle appears on the product layout.
- No(q) is the number of times the unit cell pattern appears on the characterization vehicle.
- the random component can be written as:
- CA(x) is the critical area of defect size x
- DSD(x) is the defective size distribution, as also described in"Modeling of Lithography Related Yield Losses for CAD of VSLI Circuits", W. Maly, IEEE Trans, on CAD, July 1985, ppl61-177, which is incorporated by reference as if fully set forth herein.
- Xo is the smallest defect size which can be confidently observed or measured. This is usually set at the minimum line space design rule.
- the critical area is the area where if a defect of size x landed, a short would occur. For very small x, the critical area is near 0 while very large defect sizes have a critical area approaching the entire area of the chip. Additional description of critical area and extraction techniques can be found in P. K. Nag and W. Maly,
- the defect size distribution represents the defect density of defects of size x.
- There are many proposed models for defect size distributions see, for example, "Yield Models -
- P is a unitless value which represents the rate at which defects decay over size.
- p is between 2 and 4.
- K is a normalization factor such that
- the nest structure is designed for extracting defect size distributions. It is composed of N lines of width w and space s as shown in Figure 20. This structure is tested by measuring the shorting current between lines 1 and 2, 2 and 3, 3 and 4, ..., and N-1 and N. Any current above a given spec limit is deemed a short. In addition, opens can be testing by measuring the resistance of lines 1, 2, 3, ...., N-1, and N. Any resistance above a certain spec limit is deemed to be an open line. By examining how many lines are shorted together the defect size distribution can be determined.
- the defect size must be greater than s and no larger than 3w + 2s. Any defects smaller than s will not cause a short at all while defects larger than 3w+2s are guaranteed to cause a short of at least 3 lines. For each number of lines shorted, an interval of sizes can be created:
- targets are ascribed to each module listed in the spread sheet. The further a module yield is away from a target, the more emphasis and resources are devoted to fixing the problem.
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EP00980490A EP1384179A4 (en) | 1999-11-18 | 2000-11-17 | System and method for product yield prediction |
JP2001537527A JP2004505433A (en) | 1999-11-18 | 2000-11-17 | System and method for product yield prediction |
AU17744/01A AU1774401A (en) | 1999-11-18 | 2000-11-17 | System and method for product yield prediction |
US10/200,045 US6901564B2 (en) | 1999-11-18 | 2002-07-18 | System and method for product yield prediction |
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US09/442,699 US6449749B1 (en) | 1999-11-18 | 1999-11-18 | System and method for product yield prediction |
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US20030145292A1 (en) | 2003-07-31 |
AU1774401A (en) | 2001-05-30 |
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WO2001035718A9 (en) | 2002-05-30 |
US20070118242A1 (en) | 2007-05-24 |
CN1535436A (en) | 2004-10-06 |
WO2001037150A1 (en) | 2001-05-25 |
JP2007201497A (en) | 2007-08-09 |
US6901564B2 (en) | 2005-05-31 |
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