As the proportion of LWR/CDU in the EPE budget has tightened in recent years, its reduction has become a critical issue. Among many factors, contributions of resist and speckle play a key role in LWR/CDU. The authors therefore carried out a series of experiments in which the resist compositions and the speckle were controlled in order to validate the above points. The spatial frequency of the speckle was controlled by controlling the illumination conditions of the scanner in the experiments. The experiments not only clarified the contributions of resist and speckle, but also confirmed the contribution of the interaction between resist and speckle. We were able to use PSD analysis with the results of a simplified model-based Monte Carlo simulation to explain the interaction between resist and speckle. In addition, experimental results proved that LWR/CDU reduction can be achieved by reducing speckle and optimizing resist composition.
With the advancement of semiconductor device miniaturization, the critical dimension (CD) has reached several tens of nanometers. To meet high yield demands, strict CD control is crucial. However, conventional CD measurement methods such as SEM and scatterometry have a problem; the measurement time increases in proportion to the number of measurement points. To solve this problem, we have developed a CD measurement technology that enables high density measurement of more than 100,000 points on the wafer surface in a few minutes per wafer.1 The CD value is calculated from the correlation between the diffracted light signal and CD. Despite the advantages this method provides, there still have been challenges. Measuring the critical dimensions of resist patterns of several tens of nanometers formed in EUV lithography across the entire wafer sometimes poses difficulties due to insufficient sensitivity with diffracted light, making high-precision CD measurement difficult. In this paper, we propose an enhanced measurement technique that quantifies the changes in the polarization state of diffracted light and reflected light from the wafer as Stokes parameters and calculates the CD based on the correlation between the obtained Stokes parameters and the CD value. Theoretically, it is sensitive to resist patterns of a few nanometers. For accuracy verification, we measured next-generation DRAM process wafers, including EUV-processed wafers. The minimum of measurement error, which compared with the CD value measured by SEM, achieved to 3σ = 0.57. The total time for wafer measurement and calculation processing was about a few minutes per wafer for over 10,000 points on the wafer surface.
For adopting DSA patterning technology to implementation of upcoming DRAM nodes, a novel, unique, and user-friendly wet etch process was introduced. Our concept performs for good etch selectivity in design which facilitates high resolution patterning, and potentially offers an alternative solution to conventional dry etch techniques especially where CD goes smaller with a higher aspect ratio. This paper will discuss more in detail the concept of wet chemistry and design strategy which were developed for processing PS-b-PMMA (polystyrene-b-polymethyl methacrylate) hole patterns for advanced nodes. Besides, we further open perspectives of our wet etch strategy to new process development which does not require UV cure. Preliminary experiment and successful demonstration on PS-b-PMMA-based hole patterns will also be discussed in this paper.
Directed Self-Assembly (DSA) has been reported many times in the past decade as a technique for forming fine patterns1- 12. As processes for application to the semiconductor process, the grapho-epitaxy process forms a desired pattern in an isolated area using a physical guide, and the chemical-epitaxy process forms a single pitch over a wide range using a chemical guide are typical. There are many reports regarding the line pattern formation using a lamellar phase to meet the demand for miniaturization from the mass production of semiconductors, and this is partly because the lamellar phase is relatively stable. However, for fine line pattern formation, multiplication techniques such as SADP (self-aligned double patterning) and SAQP (self-aligned quadruple patterning) have matured, and in recent years, the number of cases where EUV (extreme ultra-violet) single exposure is used is increasing. For this reason, DSA is rarely used in mass production of semiconductors. On the other hand, when miniaturizing high-density hole patterns, methods such as multiple exposure and etching, and methods of forming holes by crossing line patterns formed by SADP are relatively expensive. In addition, it is difficult to maintain the uniformity of hole CD (critical dimension) and pitch. In addition, when EUV is applied, it is not easy to suppress defects and form a wide range of patterns due to stochasticity, which has become a problem in recent years. Therefore, the formation of high-density hole patterns using DSA is attracting attention. In DSA, the hole diameter can be controlled by the molecular weight of BCP (block co-polymer), and the pitch tends to be uniform spontaneously. Also, if the chemical-epitaxy process is used, the pattern can be formed over a wide range. However, hole patterns using a cylinder phase tend to have large fluctuations in hole diameter and placement due to the high degree of freedom in placement. It is also important to what extent the established process can be extended to further miniaturization. In this presentation, we report on the hole pattern formation method by the chemo-epitaxy method and efforts to improve the fidelity for application to the semiconductor process.
The Edge-placement-error requirements keep progressively scaling down in immersion lithography process in conjunction with Immersion lightsource technology. We studied quantification analysis of impact on resist LWR/ LER to the speckle dependency by;
a. LWR/LER by analyzing the Power Spectral Density (PSD) curves.
b. key frequency components by the photo resist and/ or the speckle contrast such based on PSD tendency by # of pulse use during exposure
c. further speckle contrast reduction for LWR/ LER enhancement by 4X extension of Pulse duration.
In recent years, the number of manufacturing processes is increasing in pursuit of device pattern miniaturization. Complicated processes such as SAQP have been introduced, increasing the number of control parameters. Nevertheless, the demand for production yield enhancement is as high as ever. To detect CD changes, fixed-point measurement by using CD-SEM or scatterometry tools is typically performed, but these time-consuming measurement methods are not suitable for high-density, across-a-wafer measurement or for detecting CD anomalies that randomly occur. To address these issues, we have developed a technology that enables high-precision CD measurement of more than 100,000 points per wafer within a few minutes. It enables monitoring various CD defects in various processes such as holes and L/S patterns after photolithography, L/S patterns after SAQP/SADP, and fine hole diameters after etching. It can also measure CD imbalances after SAQP processes. In addition, it enables precisely obtaining intra-shot CD distribution based on the distribution over the entire surface of a wafer. We evaluated this technology using actual device wafers. CD imbalances of SAQP on DRAM process wafers were measured, within a few minutes across a wafer, at an accuracy of |X|+3σ<0.5 nm. CD changes at the outermost area of the wafer were captured by CD measurement of 27 nm hole patterns on a DRAM process wafer. Random CD defects were captured by CD measurement of 38 nm hole patterns on a DRAM process wafer. These defects affect device yield but were not detectable by using conventional inspection tools.
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