For many years, lithographic resolution has been the main obstacle for keeping the pace of transistor densification to meet Moore's Law. For the 45 nm node and beyond, new lithography techniques are being considered, including immersion ArF lithography (iArF) and extreme ultraviolet (EUV) lithography. As in the past, these techniques will use new types of photoresists with the capability to print 45 nm node (and beyond) feature widths and pitches.In a previous paper ("SEM Metrology for Advanced Lithographies," Proc SPIE, v6518, 65182B, 2007), we compared the effects of several types of resists, ranging from deep ultraviolet (DUV) (248 nm) through ArF (193 nm) and iArF to extreme UV (EUV, 13.5 nm). iArF resists were examined, and the results from the available resist sample showed a tendency to shrink in the same manner as the ArF resist but at a lower magnitude.This paper focuses on variations of iArF resists (different chemical formulations and different lithographic sensitivities) and examine new developments in iArF resists during the last year. We characterize the resist electron beam induced shrinkage behavior under scanning electron microscopy (SEM) and evaluate the shrinkage magnitude on mature resists as well as R&D resists. We conclude with findings on the readiness of SEM metrology for these challenges.
Initial studies are presented on the use of polysulfones as non-chemically amplified resists (non-CARs) for 193 nm immersion lithography. Polynorbornene sulfone films on silicon wafers have been irradiated with 193 nm photons in the absence of a photo-acid generator. Chemical contrast curves and contrast curves were obtained via spectroscopic ellipsometry and grazing angle -attenuated total reflectance FTIR spectroscopy. Results were consistent with previously reported mechanisms for the degradation of aliphatic polysulfones with ionizing radiation. It was shown that E0 values could be reduced significantly by using a post exposure bake step, which propagated depolymerization of the polymer. Initial patterning results down to 50 nm half pitch were demonstrated with EUV photons.
Generation-three (Gen-3) immersion lithography offers the promise of enabling the 32nm half-pitch node. For Gen-3 lithography to be successful, however, there must be major breakthroughs in materials development: The hope of obtaining numerical aperture imaging ≥ 1.70 is dependent on a high index lens, fluid, and resist. Assuming that a fluid and a lens will be identified, this paper focuses on a possible path to a high index resist. Simulations have shown that the index of the resist should be ≥ 1.9 with any index higher than 1.9 leading to an increased process latitude. Creation of a high index resist from conventional chemistry has been shown to be unrealistic. The answer may be to introduce a high index, polarizable material into a resist that is inert relative to the polymer behavior, but will this too degrade the performance of the overall system? The specific approach is to add very high index (~2.9) nanoparticles to an existing resist system. These nanoparticles have a low absorbance; consequently the imaging of conventional 193nm resists does not degrade. Further, the nanoparticles are on the order of 3nm in diameter, thus minimizing any impact on line edge roughness (LER).
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