Defect reduction has become one of the most important technical challenges in device mass-production. Knowing that
resist processing on a clean track strongly impacts defect formation in many cases, we have been trying to improve the
track process to enhance customer yield. For example, residual type defect and pattern collapse are strongly related to
process parameters in developer, and we have reported new develop and rinse methods in the previous papers. Also, we
have reported the optimization method of filtration condition to reduce bridge type defects, which are mainly caused by
foreign substances such as gels in resist. Even though we have contributed resist caused defect reduction in past studies,
defect reduction requirements continue to be very important. In this paper, we will introduce further process
improvements in terms of resist defect reduction, including the latest experimental data.
This paper reports the extracted risk issues on practical EUV resist processes and discusses verifications of them. The
risk issues were extracted with emphasis on critical dimension, defectivity and productivity for mass production EUV
resist processes. The authors verified these risk factors by utilizing available empirical knowledge. The authors found
that the micro loading effect of by-product in the resist development process was a key factor for CD uniformity. Also
discovered, was that high surface energy differences on the patterned wafers were a key factor for defectivity. As a result,
application of scan-dynamic development and dynamic scan rinse to EUV processes on a mass production level will
contribute greatly to CD and defect control as well as productivity.
One of the biggest issues in extreme ultraviolet (EUV) lithography technology is resist material development to
improve optimum exposure dose and reduce line edge roughness (LER)/ line width roughness (LWR) and resolution. In
order to attain these development targets, various kinds of challenges and innovative ideas are addressed by resist
material researchers, for instance, introduction of polymer with lower molecular weight and increase of photo acid
generator (PAG) addition amount have been presented. It is expected that these changes of resist materials will have big
influence on not only general lithography performance but also track performance.
In this paper, the application performance of EUV photoresist material, especially the spread behavior of photoresist
just after resist dispense for a coating process, is evaluated using the model resist, dynamic contact angle measurement of
resist material, dynamic drop base diameter measurement of resist droplet and so on. We have found that resist materials
with small polymer size and high PAG loading have low spread property. From these results, we propose a new
hypothesis that localized distribution of solid components that is formed just after resist dispense remains in a resist film
after pre-baking and impacts resist performance.
The device design rule is continuously shrinking toward optical resolution limit where k1 factor is below 0.3. The requirement for 193 nm photoresist below 90 nm node is quite challenging at the manufacturing phase. Using DI water rinse after development gives a significant amount of line collapse when the aspect ratio is over 3. To avoid line collapse, we co-developed special rinse solution for FIRM process with Tokyo Electron Ltd. Utilizing FIRM process, 90 nm dense line collapse was measured by CD SEM using focus-exposure matrices. The line collapse property has been observed using experimental 193 nm positive tone resist by varying monomer ratio of the polymer and process conditions. The surface property of the resist was also studied to investigate the interaction with rinse solution at the de-protected polymer region. However, a high surfactant concentration in the DI water rinse leads the swelling of the resist pattern profile. The resist component is the key to determine adequate surfactant concentration in rinse solution to minimize line collapse and pattern deformation
Exposure wavelength is being reduced significantly, along with design rule reductions. The sub-100-nm node process is currently underway with 193-nm lithography. The problems that need to be solved for the shift in wavelength from 248-nm to 193-nm lithography are those attributed to resist materials, such as plasma resistance, SEM (scanning electron microscope) shrink, and problems attributed to processes, such as pattern collapse and deposition defects (Fig. 1). Although thin films are preferable to improve resist resolution limits, pattern collapse is more likely to occur in 193-nm and 157-nm processing due to DIW (deionized water) rinse surface tension during the drying step after development. This is because of the increased A/R (aspect ratio) of the resist used to improve etching durability and lower the rigidity of 193-nm resist compared to the 248-nm resist. We had focused on controlling the capillary effect between the resist pattern and the rinse solution to avoid swelling. We evaluated the method with the use of DIW with additives rinse, and named its process “FIRM (Fishing-up by improved rinse materials)”. In this paper, we report the effectiveness of the FIRM treatment for each resist by using a dispenser of track system. We had confirmed the pattern collapse within the wafer, the process margin, CD (critical dimension) variation, CDU (CD uniformity), Defect test and, the effectiveness of the FIRM treatment in the etching process. Results indicated that the FIRM process could be used in mass production. Additionally, we had investigated application of this method to the sub-65-nm node process. We created a 55-nm line (Pitch 200-nm), with A/R = 4.47 by overdosing and performed the FIRM treatment. We were able to confirm that the FIRM treatment improved the results while all patterns had collapsed after a standard development. We believe that the FIRM treatment will be applicable to the 65-nm node.
In this study, we investigated resist pattern collapse during the resist development process. We evaluated the effect of a simple improvement such as rinse-liquid sequencing and rinsing using surfactants. First, we controlled the wafer spinning speed during the rinse-liquid flow step to reduce liquid flow shock. Using this approach, we obtained a 110-nm L/S (line and space) structure with no pattern collapse. However, this technique has only a small effect on preventing pattern collapse with sub-100-nm devices. By using a rinse process with a surfactant, we could control pattern collapse with 100-nm L/S or smaller patterns. Finally, we have succeeded in controlling pattern collapse of 70-nm L/S patterns (aspects ratio of 4.6) using a surfactant during the rinse process. These two simple methods are a significant improvement over conventional rinse processes. These process improvements are available for 90-nm (and smaller) design rules and are applicable for a single layer resists.
Reduction of critical dimension in lithography technology is aggressively promoted. At the same time, further resist thickness reduction is being pursued to increase the resolution capabilities of resist. However, thin film has its limitation because of etch requirements etc. As that result, the promotion of reduction results in increasing the aspect ratio, which leads to pattern collapse. It is well known that at drying step in developing process the capillary effect operates the photoresist pattern. If the force of the capillary effect is greater than the aggregation force of the resist pattern, the pattern collapse is generated. And the key parameters of the capillary effect are the space width between patterns, the aspect ratio, the contact angle of the D.I water rinse and the surface tension of rinse solution. Among these parameters the surface tension of rinse solution can be controlled by us. On the other hand, we've already reported that the penetration of TMAH and D.I water into the resist plays an important role on the lithographic latitude. For example, when we use the resist which TMA ion can be easily diffuse into, D.I water and TMA ion which are penetrated in the resist decreases the aggregation force of resist pattern and causes the pattern collapse even by the weak force against resist pattern. These results indicate that the swelling of photoresist by TMA ion and water is very important factor for controlling the pattern collapse. Currently, two methods are mainly tried to reduce the surface tension of rinse solution: SCF (Super Critical Fluid) and addition of additive to D.I water rinse. We used the latter method this time, because this technique has retrofittability and not special tool. And in this evaluation, we found that the degree of suppressing pattern collapse depends on the additive chemistry or formulation. With consideration given to process factors such as above, we investigated what factors contribute to suppressing pattern collapse for each resist platform when using additive-added rinse solutions. This report describes the results of our examinations and discussions of the pattern collapse mechanism.
Along with the trend of reducing the critical dimension in photolithography, exposure wavelength has been shortened from 248nm to 193nm. Resin structures of resist including their chemical characteristics have been altered from PHS to acrylate polymer. On the other hand, 2.38wt% TMAH developer solution is widely used, which was optimized at the time of 436nm resist process. However, since the resist backbone and chemical characteristics of 193nm resist are different from that of 436nm resist. So, TMAH concentration of 2.38wt% is not necessarily the best value for 193nm process and may even worsen the process latitude. Therefore, we have studied improvement of the process latitude such as CD uniformity, pattern defect, and dissolution mechanism of 193nm resist in developer solution, by applying Diluted Developer Solution (DDS) on 193nm resist process.
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