Patternable dielectric materials were developed and introduced to reduce semiconductor manufacturing complexity and
cost of ownership (CoO). However, the bestowed dual functionalities of photo-imageable spin-on dielectrics (PSOD)
put great challenges on the material design and development. In this work, we investigated the combinatorial process
optimization for the negative-tone PSOD lithography by employing the Temperature Gradient Plate (TGP) technique
which significantly reduced the numbers of wafers processed and minimized the developmental time. We demonstrated
that this TGP combinatorial is very efficient at evaluating the effects and interactions of several independent variables
such as post-apply bake (PAB) and post-exposure bake (PEB). Unlike most of the conventional photoresists, PAB
turned out to have a great effect on the PSOD pattern profiles. Based on our extensive investigation, we observed great
correlation between PAB and PEB processes. In this paper, we will discuss the variation of pattern profiles as a matrix
of PAB and PEB and propose two possible cross-linking mechanisms for the PSOD materials to explain the unusual
experimental results.
From the perspectives of IC fabrication simplification, cost reduction, and waste material cutback, it is highly desirable
to combine the traditional pattern formation step (lithographical processes) and the pattern transfer step (etch processes)
into a single step. Photo-imageable spin-on dielectrics (PSOD) render it possible to achieve the aforementioned goal.
However, the bestowed dual functionalities on PSOD put great challenges on the material design and development.
PSOD needs not only to match all the performances of the advanced resists, but also to undertake all the duties of the
dielectrics on the chips. We wish to report our modular approach employing Si-containing materials to address the
challenge and to meet the requirements from the different material roles. This paper will also discuss the investigation
and progress on lithographic performance, cure behaviors, thermal stability, and electrical and mechanical properties.
Trilayer stacks with alternating etch selectivity were developed and extensively investigated
for high NA immersion lithography at 32nm node and beyond. The conveyance of pattern transfer
function from photoresist to Si-containing bottom anti-reflective coating (Si-BARC) and carbonrich
underlayer hard-mask (UL) elegantly solved the small etch budget issue for ultra-thin
photoresists in immersion lithography. However, due to the hybrid nature of Si-BARC, many
different behaviors were observed in comparison to conventional BARC. Lithographic
performance, stability, and reworkability were among the most challenging issues for trilayer
scheme.
Despite of the rapid improvement in lithographic performance and stability of trilayer
materials reported by several papers, the rework and cleaning of trilayer materials by wet chemistry
remained a challenging problem for manufacturability. The dual function requirement of reflection
control and pattern transfer (i.e. hard-masking) for spin-on Si-BARC mandates hybrid materials.
Si-BARC containing both organic moiety and inorganic backbone were extensively studied and
demonstrated excellent performance. However, the hybrid nature of Si-BARC necessitates the
revisit of different wet chemistries and process adjustment is essential to achieve desirable results.
In addition, the similarity in chemical structures between Si-BARC and low-κ dielectrics demands
subtle rework differentiation by wet chemistry from a chemistry point of view.
In our development, we strived to identify rework solutions for trilayer materials in both
front-end-of-line (FEOL) and back-end-of-line (BEOL) applications. Rework solutions including
diluted HF, Piranha, and low-κ compatible strippers were extensively investigated. The
optimization of solution mixture ratios and processing conditions was systematically studied.
Thorough defect inspection after rework was performed to ensure the readiness for
manufacturability. Extensive Piranha rework study on stack wafers and monitor wafers were
carried out and excellent results are reported.
Trilayer stacks with alternating etch selectivity were developed and extensively investigated
for high NA immersion lithography at 32nm node and beyond. This paper discusses the
fundamental aspects of the Si-containing BARC (Si-BARC) materials with ultra-high silicon
content and carbon-rich underlayers that we developed. Designing of materials at a molecular level
is presented. It was demonstrated that this fundamental understanding assisted in achieving
satisfactory shelf life and excellent coating defect results.
Prolith® simulations using trilayer stacks showed superior reflectivity control for hyper-NA
immersion lithography. The impact of high incident angles on substrate reflectivity was analyzed
and this paper demonstrated that trilayer scheme provides wider process windows and is more
tolerant to topography than conventional single layer BARC. Extensive resist compatibility
investigation was conducted and the root causes for poor lithography results were investigated.
Excellent 45nm dense lines performance employing the spin-on trilayer stack on a 1.2 NA
immersion scanner is reported. In addition, pattern transfers were successfully carried out and the
Si-BARC with high silicon content demonstrated outstanding masking property. In comparison to
the theoretical %Si values, better correlation with etch selectivity was observed with
experimental %Si. Furthermore, this paper addresses the wet rework of trilayer materials and
results using Piranha rework are presented. Clean 12in wafers were obtained after reworking
trilayer stacks, as evidenced by defect analysis.
Spin-on trilayer materials are increasingly being integrated in high density microfabrication that use high NA ArF
lithography due to dwindling photoresist film thicknesses, lower integration cost and reduced complexity compared to
analogous CVD stacks. To guide our development in spin-on trilayer materials we have established etch conditions on an
ISM etcher for pattern transfer through trilayer hard masks. We report here a range of etch process variables and their
impact on after-etch profiles and etch selectivity with AZ trilayer hard mask materials. Trilayer pattern transfer is
demonstrated using 1st and 2nd minimum stacks with various pattern types. Etch recipes are then applied to blanket
coated wafers to make comparisons between etch selectivities derived from patterned and blanket coated wafers.
New challenges face ArF bottom antireflection coatings (BARCs) with the implementation
of high NA lithography and the concurrent increase use of spin-on hard masks. To achieve superior
reflectivity control with high NA at least two semi-transparent ARC layers, with distinct optical
indices, are necessary to effectively lower substrate reflectivity through a full range of incident
angles. To achieve successful pattern transfer, these layers in conjunction with the organic resist,
should be stacked with an alternating elemental composition to amplify vertical resolution during
etch. This will circumvent the inherent low etch resistance of ArF resist and the decreasing film
thicknesses that accompanies increasing NA. Thus, incorporating hard mask properties and
antireflection properties in the same two layer system facilitates pattern transfer as a whole rather
than just enhancing lithography. As with any material expected to exhibit multiple roles there is a
delicate balance between optimizing materials with respect to one of its roles while not impairing its
other roles. We will discuss some of these conflicts and present Si-BARCs and carbon rich
underlayers which aim to balance these conflicts. In this paper we will explore simulations aimed at
finding the best film thicknesses and optical indices, etch rate selectivity, and lithographic
performance of high silicon content and high carbon content BARC materials designed to meet the
demands of both high NA lithography and trilayer processing.
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