Process improvements attributed to the use of bottom anti-reflective coatings (B.A.R.C.s) are well documented. As our experience with these materials improves, so does our understanding of additional optimization. Recent supplier experiments suggest an increase in the thickness of AZ® BARLi (bottom anti-reflective layer i-line) solution to reduce photoresist swing curve ratios. Also, changes in thin film stack on common substrates can adversely affect the degree of photoresist reflective notching. It is therefore of extreme importance to determine optimum thickness(es) of a B.A.R.C. material to ensure maximum process potential. We will document several process effects in the conversion of a SRAM test device (0.38 -O.45jtm) from a 650A to a 2000A BARLiTM fi thickness using conventional i-line photolithography.Critical dimension (CD) uniformity and depth of focus (DOF) are evaluated. Defect density between the two processes are compared before and after etch employing optical metrology and electrical test structures. Sensitivity of overlay as a function of BARLiTM fip thickness is investigated as well.

Gate critical dimension (CD) uniformity across field is a key parameter in total gate CD control; it is especially important for highly integrated microprocessor chip with large die size and high speed. Intensive study has been conducted to reveal the impact of scanner leveling tilt, defocus and illumination distribution on CD uniformity across field. Correspondingly CD in die range, vertical-horizontal CD bias, resist side wall angle and profile have all been characterized and monitored for each individual scanner. The monitoring methodology we have established enables us to maintain these CD parameters within fairly tight control range, and also provided efficient and accurate data on tool capability and marginality for running production.

Conventional and annular illumination modes for a 248 nm DUV scanner will be discussed in this paper for their advantage and drawbacks in critical dimension (CD) control. This includes proximity of line width through pitch size, marginality of resist profile measured as sidewall angle, depth of focus (DOF) in line width variation across field/wafer, and isolated space resolution, supported by SEM and scatterometer [1] metrology. Both illumination modes have been applied in the current technology node with sub-wavelength CD, variable pitch sizes, optical proximity correction (OPC) for resolution enhancement and process control optimization. Each illumination defines process margin in exposure, focus and CD uniformity, to gain capability with improved CD control.

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