Trimethylsilanol (TMS) is a low molecular weight / low boiling point silicon-containing, airborne contaminant that has
received increased interest over the past few years as an important cause for contamination of optical surfaces in
lithography equipment.
TMS is not captured well by carbon-based filters, and hexamethyldisiloxane (HMDSO), even though captured well, can
be converted to TMS when using acidic filter media commonly used for ammonia removal. TMS and HMDSO co-exist
in a chemical equilibrium, which is affected by the acidity and moisture of their environment.
This publication shows that HMDSO is converted to TMS by acidic media at concentrations typically found in
cleanroom environments. This is contrary to published results that show a re-combination of TMS to HMDSO on acid
media.
We also demonstrate that, based on its conversion to TMS, HMDSO is not a suitable test compound for hybrid chemical
filter performance, as the apparent lifetime/capacity of the filter can be substantially skewed towards larger numbers when conversion to TMS is involved. We show lifetime test results with toluene and HMDSO on acidic and non-acidic filter media.
Appropriately designed, asymmetric hybrid chemical filters significantly minimize or eliminate the conversion of
HMDSO to TMS, thereby reducing the risk to scanner optical elements. Similarly, such filters can also prevent or reduce acid-sensitive reactions of other AMC when passing through filter systems.
The authors present results of extensive studies on the chemical behavior of low molecular weight silicon-containing
species (LMWS) and associated challenges of their analytical determination and control to prevent adverse influence
on critical optical elements of exposure tools. In their paper the authors describe a non-traditional approach to the
creation of a TMS gaseous source for filter media development and an engineering solution to the challenge of
controlling LMWS - a solution that shows a significant advantage over currently existing approaches.
With the advent of 193 nm scanners, concerns about species with the potential to deposit films on unprotected optical surfaces has uncovered a long list of reactive and condensable compounds that have occupied the efforts of exposure tool and filter system suppliers for the past several years. As more experience and data is gathered from 193 nm tools now running in volume production fabs, new classes of noncondensable, nonreactive species of concern have been discovered. Some of these compounds contain refractory elements such as Si and P and can potentially lead to permanent lens contamination. The authors describe work performed to better understand the prevalence and abundance of such refractory compounds, with special emphasis on advanced sampling and analysis methods needed to accurately characterize and quantify the species of interest. Data from used filter post-mortem analysis is compared with standard airborne sampling shows a much richer data set in which trace species can be examined. Progression of such species through a serial filter array provides new insight to filter kinetics and prediction of filter performance through life.
Airborne molecular contamination (AMC) in the form of bases, acids and condensable organic and inorganic substances threaten both costly and sensitive optics and mask pattern formation in the chemically amplified resists (CAR) used for both E-beam and laser lithography. This is particularly so for mask pattern generators due to the relatively long writing times. In the development work of the SLM-based DUV-laser mask pattern generator Sigma7300, AMC aspects have been taken into consideration from an early stage. That includes e.g. analysis and selection of construction materials and development of handling methods as well as application of chemical filtering systems. Tool manufacturer and filter supplier have together specified and designed efficient hybrid filtration systems for use in Sigma7300. This paper describes AMC aspects specific for mask pattern generators, the successful design actions of the Sigma7300 and verifying analyses of the processes.
Airborne molecular contamination monitoring and control historically meant filtration of molecular bases such as ammonia and NMP since the introduction of DUV processes at the 250 nm node. Until recently, equipment manufacturers and photoresist suppliers have primarily focused on molecular base induced resist degradation. Improvements in resist chemistries combined with new robust filtration and molecular base monitoring have allowed device manufacturers to process wafers with few concerns about yield loss due to T-topping and related resist problems. Today the industry has moved to the implementation of real-time molecular base monitoring for improved process control. As device manufacturers move production to 180 nm geometries and pilot lines develop 130 nm processes, issues of resist protection are joined by the potential degradation of lithography system optical components due to deposition of condensable organic molecules. This issue is of particular concern with the introduction of 193 nm exposure systems. The higher energy ArF source increases the probability of these and other contaminants reacting and forming films on exposed optical surfaces. Solutions for the KrF generation have already been extended and supplemented with a new generation of filtration and monitoring. As device geometries shrink, real-time molecular base monitoring is being introduced into photo tool enclosures to help process engineers better understand the impact of resist contamination relative to a few nanometers of shift in CD's and implement procedures to insure high yields are maintained and CD control is tightened. Powerful molecular base filtration complements the resist suppliers' efforts to improve resist sensitivity to molecular bases. In the latest exposure tools hybrid filtration is being introduced to remove condensable organic contaminants specifically to protect the costly optics used in 193 nm steppers and scanners. Studies have been conducted to extend filtration to include acidic species. Results of these programs are presented and potential solutions for future device generations are discussed.
The issues surrounding the sensitivity of chemically amplified DUV photoresists to molecular bases such as ammonia, NMP, TMA and related compounds, have been the sources of intensive study and numerous publications. The challenges of DUV lithography tested both the photoresist suppliers' abilities to improve resistance to chemical degradation and the equipment suppliers' abilities to control molecular bases in the wafer processing environment. The efforts of photoresist suppliers have resulted in the latest generation of resists, some of which are reported to be less sensitive to molecular base exposure. Concurrently, powerful chemical filters have been developed to be able to maintain process equipment enclosures below concentrations of one part per billion (volume) through a wide range of ambient challenge conditions.
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