Directed self-assembly (DSA) process has been introduced and developed for more than a decade as one of the alternative advanced patterning techniques in the semiconductor industry. Block copolymer (BCP) is self-assembling into the desired pattern on the lithographically defined pre-pattern on the wafer. Such a bottom-up approach is used to define the pattern which is typically hard to achieve with the traditional top-down approach. As an example, the density of the pattern can be increased with DSA by the factor of 3 or 4 from the 193i lithography pattern. Although similar dimension becomes now accessible with EUV lithography, DSA keeps its benefit; the structure is simply defined by the phase separation of materials rather than the complex light-matter interactions as required for EUV resist patterning. In this presentation, we will discuss the synergetic impact of the combination of EUV and DSA.
In this work, imec and Zeon introduce the resist with new concept and report the lithography performance. Zeon has developed a new resist (ZER02#05M) in order to improve both resolution and lithography performance because conventional Zeon resists generated worse resolution and kissing(C/H)/pinching(L/S) defects at tight pitch by top loss. The lithography performance at hexagonal contact hole (C/H) patterns with ZER02#05M is presented at ADI. For P40nm hexagonal C/H pattern in ADI by new resist, the lithography performance at CD17.5 nm in hole CD was achieved at the exposure dose of 92 mJ/cm2, giving a LCDU of 2.74 nm. It at CD18nm in P38nm hexagonal C/H pattern was resolved at 105 mJ/cm2, with a LCDU of 2.95 nm. t at CD18nm it at CD 17nm in P36nm hexagonal C/H pattern was resolved at 92 mJ/cm2, with a LCDU of 4.12 nm. Entire results with ZER02#05M could improve LCDU compared to ZER02#04DM, especially at larger CD. Additionally, patterning performance in AEI with 05 which did not optimize polymer properties could transfer patterns well and enhance LCDU compared to ZER02#04DM.
In photoresist processing a prebake is traditionally used after coating the photoresist on a wafer to drive off solvents in the resist, resulting in a more stable film. In comparison to other stages of the lithography process (e.g. the conditions of exposure and post-exposure events), limited attention is paid in the prebake optimization for the EUV application. In this work, investigation is done to clarify its role for the case of chemically amplified resists (CAR). Compared to the earlier DUV application, this resist is used at significantly smaller thicknesses and has a significantly different composition in terms of photo acid generator (PAG) and quencher types and concentration. In a first screening, a commercial CAR material – coated on Si – was investigated towards contrast changes at different prebake temperatures. It was found that lower temperature can result in adhesion failure when substrate conditions are not optimized for adhesion. With proper adhesion promotion however, it was found that prebake temperature could be lowered significantly or even omitted, without clear change in contrast. Using model resists in combination with residual gas analysis (RGA), it was found that the use of photo-decomposable quencher could be responsible for maintaining contrast to lower bake temperatures. In a second investigation, an assessment towards outgas risk was done when using resists at lower prebake temperatures in EUV scanner environment. Finally, the printability of commercial CAR was tested on the NXE3400 EUV scanner at different prebake temperatures. This was done by coating the CAR on two available underlayer materials: spin-on-glass and deposited underlayer. Results show that the prebake temperature could be reduced or even omitted without a clear deterioration in process window, line edge roughness and defectivity. It was found that proper choice of underlayer material could even improve slightly the printing performance at lower prebake condition.
Background: Polyphthalaldehyde (PPA)-based systems can be interesting candidates for extreme ultraviolet (EUV) lithography as dry development resists with simple chemistry.
Aim: We present EUV-induced mechanistic and contrast curve studies for the end-capped PPA.
Approach: Fourier transform infrared (FTIR) spectroscopy and desorption studies were conducted to understand the EUV-induced mechanistic pathway. Although, contrast curve analysis was used to check its feasibility for EUV-patterning.
Results: First, FTIR and desorption studies confirmed that the EUV-radiation is capable to remove the end-capping group and induce unzipping (direct depolymerization) reaction in the PPA polymer chain. Second, contrast curve analysis showed a gradual decrease in the film thickness with respect to the EUV dose, which is due to the low EUV sensitivity of the PPA polymer. A post exposure bake step is important to improve the contrast curve, as it helps to depolymerize any residual polymer remaining after exposure. Further, even though the polymer sublimates when exposed to the EUV radiation, eliminating the need to apply a wet development step, crosslinking at high doses causes deposition of residual film onto the wafer surface. Therefore, a thin film (below 20 nm) and a wet development process might be important to get clean patterns.
Conclusion: This study confirms that the end-capped PPA, with a simple patterning mechanism, can be a useful system for the development of new dry development resists for EUV lithography.
In this work, we report the lithography performance of main chain scission type resists exposed with the ASML NXE3300B EUV scanner. We also detail the advancements achieved in recent developments of the novel process conditions and the polymer properties of main chain scission type resist. With optimized resist thickness and resist developer, a resolution of 16 nm half-pitch for dense line-space pattern can be achieved with a low roughness but with a high dose over 70 mJ/cm2 is required for ZER01 series (based on Zeon’s resists for EB lithography). Therefore, Zeon developed ZER02 series (Zeon’s novel resists) for EUV lithography, with a modified polymer structure improving the EUV absorption. The lithographic capabilities of dense Line-Space (L/S) patterns and orthogonal contact hole (C/H) patterns with ZER02#1 is presented. For L/S pattern, a resolution of 16 nm half pitch was achieved at an exposure dose of 57 mJ/cm2, giving an unbiased LWR of 2.7 nm and an unbiased LER of 2.0 nm. For orthogonal C/H pattern, 44 nm pitch was resolved at 50.4 mJ/cm2, with a LCDU of 3.4 nm. In addition to the enhancement of the lithographic performance achieved, fundamental studies with Gel Permeation Chromatography (GPC) and Dissolution Rate Monitor (DRM) were conducted to understand the pattering mechanism of ZER02#1 under EUV exposure.
The interaction of 91.6 eV EUV photons with photoresist – in particular chemically amplified resist (CAR) – is different than exposure at 193 nm and 248 nm wavelengths. The latter is understood well and it is known that photons interact with electrons in the resist’s molecular valence orbitals (for chemically amplified resist (CAR) the photon interacts with the photo acid generator (PAG), which leads to a deprotection reaction on a polymer after a thermal catalytic reaction during a post-exposure-bake.). At EUV however, more steps are involved in the radiolysis process between the absorption of the photon and the final chemical modification. These are related to the generation of primary electrons and their decay to lower energy secondary electrons, and most of this steps are not well understood. In this paper, the reaction products from EUV and low energy electron exposure are examined using Residual Gas Analysis (RGA), which measures and analyzes the outgassing products related to the ongoing reactions. This investigation is applied firstly on a model CAR where details of the resist chemical constituents were known prior to testing. The measurement not only resolved information on the expected acid related reactions from the PAG and protection groups, but also exhibited direct scission reactions of the polymer, where some of them lead to polymerization reactions. Moreover, the measurement quantifies the balance between the different ongoing reactions, which were confirmed by contrast curve measurements. Based on learnings on the model resist, applied the measurement technique to commercial resists, where actual resist chemistry composition is not known. Despite that, it was found that information could be deduced to distinguish between acid related ongoing reactions and direct scission of reaction on the base polymer and quantify their relation. Moreover, different generations of commercial resists based on similar chemistry platform were investigated, which revealed that improvements in printing performance could be explained by PAG reaction yield increase.
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