One key challenge in sub-100 nm lithography is line pattern collapse. Pattern collapse has become an obstacle in device manufacturing processes requiring dense-high aspect ratio resist lines. In addition to pattern collapse, defect control continues to be a factor in IC manufacturing. In this study, the impact of a formulated surface conditioner, OptiPatten® Clear, with bifunctional capabilities: improved non-collapse window and defect control, was tested using a 193 nm lithographic process. To determine pattern collapse performance, 100 nm dense lines/space (L/S) and 100 nm 1:0.9 L/S were patterned into 240 nm of resist on 200 mm wafers. The wafers were then processed with developer and a formulated surface conditioner and compared to wafers processed with developer and DI water. When analyzed, wafers processed with surface conditioner had a 33% increase in Depth-of-Focus (DOF) and a 25% increase in Critical Normalized Aspect Ratio (CNAR) compared to DI water. Optical proximity effects are often credited for having a first-order influence on pattern collapse. Trench feature data was generated using an Scanning Electron Microscope (SEM) to compare the pattern collapse performance of OptiPattern Clear to DI water. The data strongly suggests optical proximity effects are a second-order factor which OptiPattern® Clear resolves. Defect performance for OptiPattern Clear was measured by comparison with a DI water baseline. A production reticle was used to process wafers patterned with 120 nm L/S with 240 nm of resist. The wafers processed with OptiPattern® Clear had similar defect performance as the DI water.
As line edge roughness (LER) becomes one of the critical lithography challenges, there is a growing interest in applying surface conditioner solutions during post-develop process to reduce LER. In this paper, we evaluated the combined effect of surface conditioners and hard bake on the post-develop LER. There is about 1nm LER reduction, as well as a significant improvement on the common process window for LER. No negative impact on CD process window was observed with the new process. In addition, preliminary etch data showed that surface conditioners have no negative impact on pattern transfer through etch.
In this paper, the standard ASML process was optimized to reduce LineWidth Roughness (LWR) while minimizing the impact on other process performance criteria such as Depth Of Focus (DOF) and Exposure Latitude (EL). The impact of classical process optimization parameters such as post exposure bake temperature and post exposure bake time were investigated together with less often varied parameters such as hard bake temperature. These parameters were studied in conjunction with novel surface conditioners to reduce LWR. The results show that a significant reduction in the LWR number can be obtained by combining the application of a dedicated surface conditioner solution with the fine tuning of other parameters such as post exposure bake and hard bake temperature. Several process parameters had to be tuned simultaneously to retain a decent process window for the fine tuned process although some EL had to be sacrificed.
The improvement in effective resolution of photo masks and templates is demonstrated by reducing pattern collapse through the use of surface conditioners. The masks were coated with a chemically amplified negative e-beam resist, FEN270, and exposed on a 50keV e-beam system. The factors investigated in this experiment included two surface conditioner (SC) formulations, SC concentration, exposure dose, post bake temperature, and resist thickness. A test pattern was designed to pinpoint the onset of resist collapse. Line sizes from 40nm to 130nm were tested with different line spacing to exert varying amounts of capillary forces on the resist walls. Surface conditioners were manually dispensed prior to the final spin dry step. The results were compared to masks processed in the same manner but with DI water as a control. OptiPattern 50% concentration surface conditioner showed the most significant resolution improvement with approximately 23nm increase from the baseline. Some adverse swelling effects were observed with some formulations.
For the next-generation immersion lithography technology, there is a growing interest in the immersion fluids having a refractive index larger than 1.5 and low absorbance at 193nm wavelength. In this paper, we report our effort in identifying new immersion fluid candidates. The absolute refractive index values and thermo-optic coefficients, dn/dT, were measured with 1x10-4 and 1x10-5 accuracy respectively at 193nm wavelength. The results showed promising candidates having refractive index ranging from 1.5 to 1.65 with low absorbance at 193nm wavelength. Preliminary imaging results with a new immersion fluid gave good 65nm Line/Space patterns. However, the minimum exposure time of 20sec is about ten times as needed for water, indicating the need to further reduce the absorbance of the immersion fluid.
Linewidth roughness (LWR) is a major challenge for 90nm node and below. As feature sizes decrease, the reliable measurement, statistical comparison and interpretation of LWR data become increasingly important. The reliability of all LWR statistical analysis methods are strongly impacted by the architecture of LWR data being analyzed. Some of the key structural aspects of the collected data include: measurement box size, distance between neighboring measurements and whether measurement boxes have been "stitched" together for analysis. Additionally, the true nature of underlying line width variation, including both cyclical and non-cyclical trends, impacts how reliable a given interpretation will be. Current statistical methodologies for linewidth data are oriented at estimation of the frequency and scale of cyclical variation in linewidth components. Fourier analysis is traditionally applied for this purpose. Such analyses assume both that there is a cyclical component (e.g., sinusoidal) or components in the data to be modeled, as well as implicitly assuming a Gaussian error distribution for the linewidth variation that remains after modeling. The assumption that Fourier analysis is appropriate for LWR data often not met in practice by the LWR data undergoing analysis. A more model-independent approach, distance-based standard deviations, is proposed for use as part of an LWR statistical analysis methodology. It is based on the calculation of local standard deviations of linewidth for all possible distances between measured points. This methodology permits the statistical comparison of linewidth roughness over any distance of interest and makes efficient use of all data for a given measurement box length. It can determine the minimum measurement box length required to capture all linewidth variation. In addition, the method can confirm the validity of line stitching to increase measurement box size, and locate the sources of variance in the overall LWR value (e.g. line-to-line vs. within line). This new method is an effective alternative to established methods for the statistical evaluation of linewidth data. The new statistical technique will be illustrated on linewidth data (measured in μm) obtained from CDSEM measurements.
In this paper, surface conditioners were applied during the post-develop process to extend the capability of 248nm lithography processing below the k1= 0.30 threshold. The interaction between surface conditioner and photoresist was found to be a critical parameter in affecting pattern collapse, line width roughness (LWR), and process latitude. Tailoring the surface interaction properties required balancing between surface conditioners that had weak interactions that improved pattern collapse only marginally, to surface conditions with strong interactions that produced a considerable reduction in LWR but provided no benefit to pattern collapse or process latitude when compared to DI water. The surface conditioners with optimized resist interactions provided significant improvement in all performance parameters including reduced pattern collapse, improved LWR, and enlarged usable process latitude.
As linewidths continue to decrease in size, preventing smaller defects is becoming critical to maintaining yield. Defects that are caused during the development cycle and attach themselves to the BARC surface, such as water spots or photoresist residues, have always been a concern and have been usually removed at the expense of throughput. Various options are available to reduce these types of defects but each has disadvantages. One such example is a double puddle develop process. The disadvantage of this process is that the exposure dose may have to be changed. Another example is increasing the rinse time to several minutes with an associated reduction in throughput. This paper will discuss rinse alternatives that have been able to reduce develop type defects by up to 70% while also reducing the wafer-to-wafer variation by up to 80%. This process may have a dramatic increase in throughput by keeping the total rinse time under 20 seconds and may have minimal (less than 2% change) impact on measured linewidth. These rinse processes utilize a quick succession of changing spin speeds and accelerations that are acceptable for 300-mm wafer processing. Surfactant-containing rinse solutions designed to reduce line collapse in 193-nm photoresists were also investigated to determine their effectiveness in reducing post-develop defects in concert with the newly developed water rinse process. The rinse processes that will be discussed will have the flexibility of integrating the surfactant-containing rinse solution while maintaining the shortest possible cycle time. At the same time these processes will reduce defects and pattern collapse.
As pattern collapse and line width roughness (LWR) become critical lithography challenges, there is growing interest in applying surface conditioner solutions during the post-develop process to address BOTH these issues. In this paper, we patterned 90nm 1:1.2 lines/spaces (L/S) on 200mm wafers and 70nm dense lines on 300mm wafers to evaluate the combined performance of pattern collapse and LWR using newly formulated surface conditioners. The performance of each conditioner was compared to the standard formulation, which is capable of significant pattern collapse reduction, but affords no LWR improvement. These newly improved formulations enabled a ~20% LWR reduction for 90nm features and a ~10% LWR reduction for 70nm dense lines. In addition, the new formulations significantly enlarged the LWR and CD process windows for 70nm dense lines, as demonstrated by a 50% increase of maximum depth of focus (DOF) over the standard formulation.
In this study, surface conditioning solutions were used during post-develop process to enhance the 193 nm lithography performance. These solutions were applied to the wafer surface in a surface treatment step between the DI water rinse and drying steps. Compared to the standard develop process, the formulated surface conditioning solution enabled a 24% reduction in line width roughness, particularly in the high frequency roughness components. The solution also improved the pattern collapse performance by enlarging the non-collapse window and extending the minimum CD feature size by 10 nm. Additional benefits provided by the formulated surface conditioner solution were minimal changes to CD and resist profile.
Recently, there has been a growing interest in using surface conditioning solutions to solve the pattern collapse challenge. In this study, we investigated both pattern collapse and defect performance of surface conditioning solutions on multiple 193 nm resist systems. While the surface conditioning solutions were able to reduce the pattern collapse with good defect control with a majority of resist systems, it can increase the defect level on certain resist. Shortening the surface treatment step and optimizing the formulation can reduce the defect counts to the control level without compromising pattern collapse performance. This study also demonstrated that the surface conditioning solution is compatible with 248 nm processing, enabling the patterning of 90 nm 1:1.2 pitch lines.
Surfactant-formulated developers were utilized to enhance the CD performance for 365nm (I-line), 248nm (DUV) and 193nm resist processing. From one generation to the next, the resist surface becomes more and more hydrophobic, creating the need for enhanced surface wetting. Contact angle measurement of surfactant-formulated developers on different generations of resist surfaces, from 365nm to 157nm resist surfaces, indicated improved wetting. On-wafer testing showed significant improvement on CD uniformity with surfactant-formulated developers for 365nm, 248nm and 193nm processing. Faster development rates were also observed for chemically amplified resist systems, including 248nm, 193nm and 157nm.
In this study, surfactant-formulated developer and rinse solutions were used to enhance the performance of a 193 nm lithography process. The wetting and interfacial characteristics of surfactant-formulated solutions were studied and utilized as a screening tool for optimum formulation. The selected formulation was compared to the non-formulated TMAH development and DI water rinse process. Surfactants in developer and rinse solution significantly reduced pattern collapse, enabling an 86% increase of critical normalized aspect ratio. This corresponds to an increase in the usable resist thickness for an 80 nm 1:1 feature from 179 nm to 332 nm. Additional benefit provided by surfactant formulated process was a 25% improvement on both within-wafer and wafer-to-wafer critical dimension uniformity.
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