We applied the immersion lithography to get 32 nm node pattern with 1.55 NA, without using double exposure /
double patterning. A chromeless phase shift mask is compared with an attenuated phase shift mask to make 32 nm
dense 1:1 line and space pattern. We compared the aerial image, normalized image log slope, exposure latitude,
and depth of focus for each mask type in order to see the effect of the post exposure bake and acid diffusion length.
The process window shrinks fast if the diffusion length is larger than 10 nm for both mask types. However, up to
20 nm diffusion length, 32 nm can be processible if the exposure latitude of 5% is used in production.
In principle, the dose should not be changed to make the same linewidth if a perfect anti-reflection coating (ARC) is
used for all the sublayers underneath the resist. However, the optimum dose for different sublayers and thicknesses are
different even though perfect ARC is used. The post exposure bake (PEB) process of a chemically amplified resist is one
of the key processes to make very small features of semiconductor device. The photo-generated acid makes the
deprotection of protected polymer, and this deprotection highly depends on the PEB temperature and time. The diffusion
length of acid is also strongly dependent on PEB temperature and time. As the linewidth of the device decreases, smaller
diffusion length is required to reduce the roughness of the line edge and width.
One of the key factors to determine the deprotection and acid diffusion is the initial temperature rising and the final real
temperature inside the resist. The unpredictable temperature rising to the pre-set temperature mainly causes the variation
of linewidth and the optimum dose. In order to predict the accurate PEB temperature and time dependency of the
linewidth and dose, the heat transfer from the hot plate to the resist on the top of the multiply stacked sublayers over the
silicon wafer has to be known since the reaction and diffusion occur inside the resist, not on the top of the bare silicon
wafer. We studied heat transfer from the hot plate to the top of the resist including conductivity and thickness of each sublayer.
For this purpose, a novel numerical approach incorporated with analytic method was proposed to solve the heat
conduction problem. The unknowns for temperature are located only at the interfaces between layers, so that it is fast and
efficient. We calculated the time that is consumed for the resist to attain the prescribed PEB temperature for the different
multi stacks and thicknesses. Calculation shows that the temperature rising is different and final temperature on top of the resist is also different for
various sublayers and thicknesses of theirs including resist itself. Experiment by us and others also clearly show that
there is a definite temperature difference between on top of the bare wafer and on top of the resist. The effects for the
different layer stacks and thicknesses are investigated to obtain proper dose and linewidth control due to different actual
resist PEB temperature.
Resolution enhancement technology (RET) refers to a technique that extends the usable resolution of an imaging
system without decreasing the wavelength of light or increasing the numerical aperture (NA) of the imaging tool. Offaxis
illumination (OAI) and a phase shift mask (PSM) are essentially accompanied by optical proximity correction
(OPC) for semiconductor device manufacturing nowadays. A chromeless PSM (CLM or CPL) is compared to an
attenuated PSM (att.PSM) to make 45 nm dense line and space pattern. To obtain the best possible resolution, a proper
OPC is required with CPL and the most common application of OPC technique is the use of space bias. The optical
system with a high numerical aperture (NA), a strong OAI, and a proper polarization can decrease the k1 value well
below 0.3. CPL has various advantages over alternating PSM such as no necessity of double exposure, small pattern
displacement, and no CD error caused by the intensity imbalance. But CPL has some disadvantages. In the case of 100 %
transmittance pure CPL, there is no shading material that is usually deposited on the line pattern for both att.PSM and
alternating PSM to control the line width. Because of no shading material for CPL, the required resist critical dimension
(CD) has to be obtained by using phase only and it is difficult to control the resist CD through pitch. As expected, CPL
needs smaller dose than att.PSM to make the desired 45 nm CD with 0.94 NA. Our simulation results showed that 10 nm
negative bias is optimum for CPL mask. We demonstrated that CPL mask and att.PSM technology can be used to make
45 nm node by the negative space bias.
50 nm random contact hole array by resist reflow process (RRP) was studied to make 32 nm node device. Patterning
of smaller contact hole array is harder than patterning the line and space. RRP has a lot of advantages, but RRP strongly
depends on pattern array, pitch, and shape. Thus, we must have full knowledge for pattern dependency after RRP, and
then we need to have optimum optical proximity corrected mask including RRP to compensate the pattern dependency in
random array.
To make optimum optical proximity and RRP corrected mask, we must have better understanding that how much resist
flows and where the contact hole locations are after RRP. A simulation is made to correctly predict RRP result by
including the RRP parameters such as viscosity, adhesion force, surface tension and location of the contact hole. As a
result, we made uniform 50 nm contact hole patterns even for the random contact hole array and for different shaped
contact hole array by optical proximity corrected RRP.
Microlithography has shown an amazing development over the last decade and has continued to be one of the critical
success factors for enabling ever smaller feature sizes. The fabrication of leading edge devices strongly relies on the use
of chemically amplified resist, where the post exposure bake (PEB) is among the most important process steps for
obtaining smaller feature size with better linewidth control. PEB sensitivity is defined as the dependency of pattern size
(or critical dimension, CD) variation on the perturbation of the PEB temperature and time throughout this paper. From
the beginning of ArF (193 nm) lithography, PEB sensitivity becomes serious problem because ArF photoresist shows
very severe dependency on PEB temperature and time. PEB sensitivity relies largely on photo-generated acid diffusion.
If acid diffusion can be effectively controlled, PEB sensitivity will be improved. As pattern size decreases for a higher
density device, this variation can be more than 10% of target CD. Therefore, PEB sensitivity and diffusion length
becomes very important property for sub-90 nm pattern. This paper demonstrates the effect of acid diffusion length for
each PEB temperature and time for the mask types of attenuated and chromeless phase shift mask. Differences can
between the attenuated and chromeless phase shift masks as functions of PEB temperature and time and develop time.
We compared the acid diffusion lengths as a function of PEB time. And we calculated acid distribution as functions of
PEB time and diffusion length. CD uniformity, thickness loss and exposure latitude are also compared.
The crystal growth and haze formation on the reticle continue to be significant problems for the semiconductor industry. Recently, a pattern size has gradually reduced to enhance the integration of semiconductor device. As minimum linewidth has shrunk, the exposure wavelength has also progressively shrunk. The exposure wavelengths have been reduced progressively from g-line (436 nm), i-line (365 nm), KrF (248 nm), to ArF (193 nm). However, expose wavelength shrink caused some serious problems. One of the problems to be solved is growing defect in the reticle during the process. This growing defect on the reticle is called the haze. The haze is formed on both sides of the reticle, on the quartz side of the mask and on the chrome side of the mask. In this investigation, we varied the local haze defect size and the characteristics of the haze defect. And we get the critical dimension and the exposure latitude variation as the haze transmission changes and the haze phase shifts.
Pattern collapse for line widths under 32 nm printed by extreme ultra-violet lithography (EUVL) is investigated by using commercial tools. Pattern collapse phenomenon occurs very often in actual process. Pattern collapse means that pattern is bending, peel-off, and break of the resist, thus it affects the production and yield of semiconductor. In this paper, we newly defined and investigated the critical aspect ratio. Pattern collapse happens if the critical aspect ratio is smaller than aspect ratio. Because EUV resist has smaller adhesive strength than currently available DUV and ArF resists, EUV resist easily collapse more easily than DUV resist does. This phenomenon is successfully modeled.
Each generation of semiconductor device technology drives many new and interesting resolution enhancement technologies (RET). As minimum feature size of semiconductor devices have shrunk, the exposure wavelength has also progressively shrunk. The 193 nm lithography for low-k1 process has increased the appearance of progressive defects on masks often known as haze or crystal growth. Crystal growth on a mask surface has become an increasing issue as the industry has adopted a 193 nm wavelength in order to increase lithographic resolution and print ever decreasing device line width. Haze is known to be a growing defect on photomask as a result of increased wafer lithography exposure and photochemical reactions induced by combination of chemical residuals on the mask surface. We build experimental system to create and detect the haze growth. A photomask is enclosed in a glove box where the atmosphere and exposure conditions are controlled and monitored throughout the exposure processing. A test photomask is exposed to accumulate the dose of laser radiation. And then spectroscopic ellipsometry and metallographic microscope techniques are used to check the surface conditions of the masks before and after the laser exposure. We found that spectroscopic ellipsometry measurement values of Δ and Ψ were changed. The results of the spectroscopic ellipsometry analysis show the change of the haze thickness on mask surface. Thickness and roughness of the mask surface is increased with the exposure. This means that haze grows on the mask surface by the exposure. Masks become useless due to transmission loss or defect generation, which is directly related to the formation of the haze. The haze causes the increase of mask thickness, transmission drop and affects the formation of pattern. So, we investigated the linewidth variation and the process window as a function of haze size effect with Solid-E of Sigma-C.
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