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.
To meet the challenges for resist materials raised by high resolution lithography technologies, tailor-made photoacid
generators (PAGs) with controlled acid diffusion and improved miscibility with polymers are very important. We have
developed new ionic PAGs containing functionalized semifluorinated sulfonates. These PAGs have excellent solubility
in polymer matrices and common organic solvents, high thermal stability, high acid strength and low volatility of the
generated acids, and make them attractive PAGs for high resolution lithography. In this contribution, the preparation and
characterization of several new ionic PAGs, the influence of the host matrix on PAG properties, and a comparison of
their lithographic performance are presented. Specifically their lithographic performance at EUV wavelength is
discussed.
The ability of the semiconductor industry to reduce device dimensions below 45 nm is hindered
by limitations in both resist material and processing techniques. High resolution and sensitivity
along with low line edge roughness are key requirements of next generation resist materials. In
order to meet future demands of the semiconductor industry, new resist design strategies are being
considered. In the past few years, we have focused on developing small molecule resists capable
of high resolution patterning. Despite their small size, these molecules known as molecular glasses
can be designed to demonstrate high glass transition temperature (Tg) comparable to polymeric
resists. Several ring and branched architectures with high Tg values that have attained feature
resolution as small as 30nm through Extreme Ultraviolet (EUV) exposure will be discussed. In
addition to potential performance advantages, the small size of these resist molecules also allows
solvent free processing techniques to be utilized. Our efforts on physical vapor deposition and
supercritical CO2 development of molecular glass resists will also be highlighted. Furthermore, we
are also investigating hybrid resist materials by combining short polymeric arms with various
molecular glass cores. These innovative architectures are being explored at 193nm wavelength
through fundamental structure - property analysis.
Nonionic photoacid generators (PAGs) based on photosensitive fluoroorganic sulfonate esters of imide and nitrobenzyl have been prepared and characterized. These new compounds produce fluoroorganic sulfonic acids that contain very few fluorine atoms (non-PFOS), which make them attractive PAGs for all advanced and emerging lithography. The structural influence of these new PAGs on sensitivity, resolution and line edge roughness (LER) was investigated by using DUV (254 nm) and e-beam lithography with ESCAP and ACRYLIC type positive tone resists. E-beam lithography evaluation indicates that these new fluroorganic sulfonic acids are sensitive and capable of providing image profiles down to 80 nm. The variation observed in sensitivity and LER at e-beam lithography was analyzed in terms of the structures of the photogenerated acids, chromophores and resists.
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