Photo Mask Dummy Patterns for Electron Beam Proximity Effect

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Solution Overview

Problem

The semiconductor industry faces challenges in achieving finer pattern resolution in photo masks due to the diffraction of light and the electron beam proximity effect, which limits the resolution and uniformity of patterns transferred to the wafer photoresist.

Innovation Solution

The introduction of non-printable dummy patterns in the photo mask design, which are smaller than the resolution limit of the electron beam lithography tool, helps to suppress the electron beam proximity effect and electrical charging effects. These dummy patterns are strategically placed in areas with low pattern density to adjust the overall pattern density and improve resolution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the pattern size is reduced to achieve finer resolution, then the manufacturing precision is improved, but the electron beam proximity effect increases causing loss of resolution

Engineering Contradiction:
Improvepattern resolutionVSAvoidelectron beam proximity effect
Core Design Contradiction:
Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent applies local quality by introducing dummy patterns specifically in low-density regions adjacent to high-density pattern areas. This creates a non-uniform distribution of patterns where the density varies locally to compensate for the electron beam proximity effect, which is most severe at boundaries between high and low density regions. The dummy patterns are strategically placed to provide local density adjustment without affecting the overall circuit design.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements preliminary anti-action by pre-calculating the electron beam proximity effect and compensating for it through the addition of dummy patterns before the actual lithography process. The proximity effect calculation unit computes the expected blur and distortion, and the dummy patterns are designed in advance to counteract these effects, ensuring that the final pattern after exposure matches the intended design.

Inventive Principle:
Principle #9Preliminary anti-action

2Manufacturing precision

If the pattern density is increased to improve resolution, then the manufacturing precision is improved, but the electrical charging effects increase causing non-uniformity

Engineering Contradiction:
Improvecritical dimension uniformityVSAvoidelectrical charging effects
Core Design Contradiction:
Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent uses local quality by creating regions with different pattern densities to balance electrical charging effects. High-density regions are compensated with surrounding dummy patterns to prevent excessive charging, while low-density regions receive dummy patterns to prevent insufficient charging. This local adjustment ensures uniform critical dimensions across the entire mask.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies parameter changes by modifying the pattern density parameter through the addition of dummy patterns. The pattern density is adjusted locally in different regions of the mask to optimize the electrical charging characteristics during electron beam exposure, thereby achieving uniform critical dimensions across varying pattern densities.

Inventive Principle:
Principle #35Parameter changes

3Adaptability or versatility

If the pattern density varies significantly across the mask, then the design flexibility is improved, but the resolution uniformity deteriorates

Engineering Contradiction:
Improvedesign flexibilityVSAvoidresolution uniformity
Core Design Contradiction:
Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent maintains design flexibility while achieving resolution uniformity through local quality adjustment. The dummy pattern generation unit independently processes each high-density region and its surrounding low-density areas, allowing the overall circuit design to remain flexible while locally optimizing each region's pattern density to ensure uniform resolution across the entire mask.

Inventive Principle:
Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The use of non-printable dummy patterns enhances the critical dimension (CD) uniformity and resolution of the photo masks, addressing the limitations of existing technologies and enabling the fabrication of semiconductor devices with finer feature sizes.

Implementation Method 1

patterns are drawn by using an electron beam from an electron beam lithography apparatus on a resist layer formed on a mask blank substrate

Methodology Applied
Scientific EffectElectron beam: Electron Beam

Implementation Method 2

the diffraction of light at feature pattern edges formed on the reticle causes a loss of resolution in transferring the reticle pattern to the wafer photoresist

Methodology Applied
Scientific EffectDiffraction: Diffraction

Data Source

PatentUS12298673B2Method of manufacturing photo masks
Publication Date: 2025.05.13 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD
  • US12298673B2 patent drawing
  • US12298673B2 patent drawing
  • US12298673B2 patent drawing

AI summary

In a method of manufacturing a photo mask for lithography, circuit pattern data are acquired. A pattern density, which is a total pattern area per predetermined area, is calculated from the circuit pattern data. Dummy pattern data for areas having pattern density less than a threshold density are generated. Mask drawing data is generated from the circuit pattern data and the dummy pattern data. By using an electron beam from an electron beam lithography apparatus, patterns are drawn according to the mask drawing data on a resist layer formed on a mask blank substrate. The drawn resist layer is developed using a developing solution. Dummy patterns included in the dummy pattern data are not printed as a photo mask pattern when the resist layer is exposed with the electron beam and is developed.