Anthony R. Forte

Line-edge roughness in sub-0.18-μm resist patterns

We have characterized line-edge roughness in single-layer, top-surface imaging, bilayer and trilayer resist schemes. The results indicate that in dry developed resists there is inherent line-edge roughness which results from the etch mask, resist (planarizing layer) erosion, and their dependence on plasma etch conditions. In top surface imaging the abruptness of the etch mask, i.e., the silylation contrast, and the silicon content in the silylated areas are the most significant contributors to line-edge roughness. Nevertheless, even in the case of a trilayer, where the SiO2 layer represents the near ideal mask, there is still resist sidewall roughness of the planarizing layer observed which is plasma induced and polymer dependent. The mechanism and magnitude of line-edge roughness are different for different resist schemes, and require specific optimization. Plasma etching of silicon, like O2 dry development, contributes to the final line-edge roughness of patterned features.

A high-power MEMS electric induction motor

An electric induction micromotor with a 4-mm-diameter rotor was designed and built for high-power operation. Operated at partial actuating voltage, the motor has demonstrated an air gap power in excess of 20 mW and torque of 3.5 /spl mu/Nm at speeds in excess of 55 000 rpm. Operation at higher power and speed was limited by bearing stability at higher rotational speeds. The device builds on an earlier micromotor demonstrated by Frechette et al. The high power of the present motor is enabled by its low-loss, high-voltage electric stator, which also offers improved efficiency. The development of this electromechanical device is an important enabling step not only for watt-scale micromotors, but also for the development of microelectric generators. This paper presents the motors design, the fabrication process that was created to meet its stringent design requirements, and its performance to date.

Limits to etch resistance for 193-nm single-layer resists

An important aspect of single-layer resist use at 193-nm is the inherently poor etch resistance of the polymers currently under evaluation for use. In order to provide the information necessary for resist process selection at 193 nm, we have projected the ultimate etch resistance possible in 193-nm transparent polymers based on a model we have developed. First, a data base of etch rates was assembled for various alicyclic methacrylates. This data base has been used to develop an empirical structure-property relationship for predicting polymer etch rates relative to novolac-based resist. This relationship takes the functional form normalized rate equals -3.80r3 plus 6.71r2 minus 4.42r plus 2.10, where r is the mass fraction of polymer existing as cyclic carbon. From this analysis, it appears as though methacrylate resists equal in etch resistance to deep UV resists will be possible. Early generations of methacrylate-based 193-nm resists were also evaluated in actual IC process steps, and those results are presented with a brief discussion of how new plasma etch chemistries may be able to further enhance resist etch selectivity.

Lithography at a wavelength of 193 nm

The trend in microelectronics toward printing features 0.25 μm and below has motivated the development of lithography at the 193-nm wavelength of argon fluoride excimer lasers. This technology is in its early stages, but a picture is emerging of its strengths and limitations. The change in wavelength from 248 to 193 nm requires parallel progress in projection systems, optical materials, and photoresist chemistries and processes. This paper reviews the current status of these various topics, as they have been engineered under a multiyear program at MIT Lincoln Laboratory.

Optimization of a 193-nm silylation process for sub-0.25-um lithography

We have optimized a positive-tone silylation process using polyvinylphenol resist and dimethylsilyldimethylamine as the silylating agent. Imaging quality and process latitude have been evaluated at 193 nm using a 0.5-NA SVGL prototype exposure system. A low- temperature dry etch process was developed that produces vertical resist profiles resulting in large exposure and defocus latitudes, linearity of gratings down to 0.175 micrometers , and resolution of 0.15-micrometers gratings and isolated lines.

193-nm lithography

The trend in microelectronics toward printing features 0.25 /spl mu/m and below has motivated the development of lithography at the 193-nm wavelength of argon fluoride excimer lasers. This technology is in its early stages, but a picture is emerging of its strengths and limitations. The change in wavelength from 248 to 193 nm will require parallel progress in projection systems, optical materials, and photo-resist chemistries and processes. This paper reviews the current status of these various topics as they have been engineered under a multiyear program at MIT Lincoln Laboratory. >

All-dry resist processes for 193-nm lithography

We report on two different all-dry resist schemes for 193-nm lithography, one negative tone and one positive tone. Our negative tone resist is an extension of our initial work on all-dry photoresists. This scheme employs a bilayer in which the imaging layer is formed by plasma enhanced chemical vapor deposition (PECVD) from tetramethylsilane (TMS) and deposited onto PECVD carbon-based planarizing layers. Figure 1 shows SEMs of dark field and light field octagons patterned in projection on Lincoln Laboratorys 0.5-NA 193-nm Micrascan system. These 0.225-micrometers and 0.200-micrometers line and space features were obtained at a dose of approximately 58 mJ/cm2. Dry development of the exposed resist was accomplished using Cl2 chemistry in a helicon high-ion-density etching tool. Pattern transfer was performed in the helicon tool with oxygen-based chemistries. Recently, we have also developed an all-dry positive-tone silylation photoresist. This photoresist is a PECVD carbon-based polymer which is crosslinked by 193-nm exposure, enabling selective silylation similar to that initially reported by Hartney et al., with spin-applied polymers. In those polymers, for example polyvinylphenol, the silylation site concentration is fixed by the hydroxyl groups on the polymer precursors, thus limiting the silicon uptake per unit volume. With PECVD polymers, the total concentration of silylation sites and their depth can be tailored by varying plasma species as a function of time during the deposition. This affords the possibility of greater silicon uptake per unit volume and better depth control of the silylation profile. Figure 2 shows a SEM of 0.5-micrometers features patterned in plasma deposited silylation resist.

Metrology methods for quantifying edge roughness: II

Advanced scanning electron and atomic force microscopy technique have been developed to quantify line-edge and sidewall roughness in patterned resist and silicon feature with nanometer scale accuracy. Both techniques are able to follow small changes in the line-edge roughness. The measurement repeatability of the scanning electron and atomic force microscope was characterized and is 0.1 and 0.6 nm, respectively. Any roughness measured in the single layer resist mask transfers to the underlying silicon throughout a range of pattern transfer conditions. Within the measurement precision, silicon pattern transfer does not appear to decrease or increase the sidewall or line-edge roughness. An attempt to quantify the edge-roughness spatial frequency is discussed. The scanning electron microscope is still recommended over the atomic force microscope for line-edge roughness measurements based on sample throughput.

193-nm lithography (Review Paper)

The trend in microelectronics toward printing features 0.25 micrometers and below has motivated the development of lithography at the 193-nm wavelength of argon fluoride excimer lasers. This technology is in its early stages, but a picture is emerging of its strengths and limitations. The change in wavelength from 248 to 193 nm will require parallel progress in projection systems, optical materials, and photoresist chemistries and processes. This paper reviews the current status of these various topics, as they have been engineered under a multi-year program at MIT Lincoln Laboratory.