Recent advancements in extreme ultraviolet (EUV) lithography have greatly enhanced the manufacturing of fine semiconductor nodes in high volume production (HVM). With the introduction of high NA (numerical aperture) EUV, further miniaturization is expected, and it is necessary to develop lithography technology to accommodate this. Chemically amplified resist (CAR) is widely used in HVM due to their stability and advantages as metal–free resists, and adapting CAR to the High–NA EUV era has important implications. Achieving high resolution in EUV involves a trade–off between resolution, line width roughness (LWR), and sensitivity. Reducing roughness is especially important because roughness can cause pattern defects. This paper aims to reduce CAR roughness and improve the trade–off. We investigated the reduction of roughness through a post–development treatment applied to EUV–exposed patterns. To examine the influence of this post–development treatment, we performed a power spectral density (PSD) analysis of LWR. Additionally, we compared the cross–sectional shape of resist patterns before and after treatment to understand the reactions occurring within the resist. The results showed that the LWR decreased by 13.1% for 44nm line/space (L/S) pitch and 4.0% for 28nm L/S pitch after the post–development treatment. Of particular interest, the use of additional processing demonstrated the potential to reduce low–frequency roughness, which is normally very challenging. These results show the potential for the application of CAR in next–generation lithography.
As the semiconductor industry continues to push the limits of integrated circuit fabrication, reliance on extreme ultraviolet lithography (EUVL) has increased. Additionally, it has become clear that new techniques and methods are needed to mitigate pattern defectivity and roughness after lithography and etch processes and eliminate film-related defects. These approaches require further improvements to the process chemicals and the lithography process equipment to achieve finer patterns. The ESPERTTM (Enhanced Sensitivity develoPER TechnologyTM) technique has been developed and optimized to fulfil this novel development need. The ESPERTTM has demonstrated a capability that can enhance the developing contrast between the EUV exposed and unexposed areas. This paper reviews that 23 nm pitch line and space and sub-40 nm pitch pillars patterns were realized by high NILS illuminations with 0.33 NA single exposure, and we will show the ESPERTTM helped reduce the minimum critical dimension size, defectivity and roughness at the finer patterns.
One of the key steps in the pattern formation chain of extreme ultraviolet (EUV) lithography is the development process to resolve the resist pattern after EUV exposure. A simple traditional development process might be insufficient to clear the holes in contact-hole (CH) patterns and often causes missing hole defects around target-CD. In prior papers, a new development method named ESPERT™ (Enhanced Sensitivity develoPER Technology™) has been introduced to improve the performance of metal oxide-resists (MOR) for line/space (L/S) and pillar patterns. ESPERT™ as a chemical super resolution technique effectively apodized the MOR chemical image, improving chemical gradient and reducing scums. In this work, this development technique was optimised for CH patterns to reduce both the local CD uniformity (LCDU) and to reduce the levels of missing contact holes at a lower exposure dose. This is made possible thanks to the capability of the updated version of ESPERT™ that can effectively remove the scums (resist residues) inside CH to extend the missing hole defect margins. The high development contrast of the new development technique results also in a much higher exposure latitude. Using 0.33 NA EUV scanners on 36-nmpitch hexagonal patterns, the new development enhanced exposure latitude (EL), failure free latitude (FFL), and failure free dose ranges at both ADI (after development inspection) and AEI (after etch inspection) for two diverse types of MORs. For instance, in the case of the reference MOR developed by ESPERT™, CHs were nicely transferred to a TiN layer, even for small CD holes of 14.7 nm. If compared to the data by conventional development, using the new method, the EL was increased from 16.0% to 49.1%, the FFL was extended from 2 nm to 6 nm, and the failure free dose range was increased from 13.3% to 72.2%. It was also possible to have EUV dose-to-size (DtS) of 28 mJ/cm² with EL of 49.9% at ADI, using the new development. With all those advantages, this new development method is expected to be the solution for CH pattern formation of negative tone MORs in EUV lithography.
Extreme ultraviolet lithography (EUVL) has overcome significant challenges to become an essential enabler to the logic and memory scaling roadmap. Despite its significant progress, resist photo speed, and defectivity remains the main concerns for high-volume manufacturing. To overcome these issues, high-performance EUV resist processes are needed. The high-performance resist process must simultaneously meet multiple requirements, such as a high resolution, high sensitivity, low roughness, low defect level, and good global CD uniformity (CDU). One of the high-performance resist candidates for future EUV scaling, and high NA EUV is Metal Oxide Resist (MOR). In our work, we introduce the new coater/developer hardware and new resist development techniques to improve photo speed, defectivity, and CDU without degradation of roughness in MOR. We will show that the new development methods significantly improve EUV dose to size (DtS) and micro-bridge (MB) while maintaining resist roughness performance post litho and post-etch. The new coater/developer hardware and processes are evaluated through a robust characterization methodology that includes an understanding of the defect modes at ADI (after development inspection) and AEI (after etch inspection), as well its ultimate correlation to electrical yield.
As the semiconductor industry continues to push the limits of integrated circuit fabrication, reliance on extreme ultraviolet lithography (EUVL) has increased. Additionally, it has become clear that new techniques and methods are needed to mitigate pattern defectivity and roughness at lithography and etching and eliminate film-related defects. These approaches require further improvements to the process chemicals and the lithography process equipment to achieve finer patterns [1]. This paper reviews the ongoing progress in coater/developer processes to enable EUV patterning with sub-30 nm line and space and sub-40 nm pillars by using metal oxide resist (MOR). We show that combining new material with optimized illumination and processes helped reduce the minimum critical dimension size, defectivity, and roughness
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