Gary T. Spinillo

Design of a bottom antireflective layer for optical lithography

The advent of deep-UV(DUV), chemically amplified, acid catalyzed photoresists as successors to positive diazoquinones photoresists has brought about a new set of process environment concerns directed towards all materials in contact or absorbed by the photoresists. In addition to the application of DUV bottom anti-reflective coatings (BARCs) to suppress optical reflection and subsequent linewidth distortion, we must consider the properties and interaction of the BARC layer with the labile photoacid of the latent image. In this regard, we have examined the physico-chemical aspects of the DUV BARC with regards to acting as a barrier layer to substrate poisoning, and as an optical absorbing layer that does not interact and/or distort the deep-UV profile. Various single component polymeric BARCs were synthesized and examined. Considerations will be discussed of the optical absorbance, the coating quality, dry etch rate, and the impermeability of the BARC layer to photoacid diffusion to fulfill the performance requirements of BARCs for DUV lithography.

Negative tone aqueous developable resist for photon, electron, and x-ray lithography

The use of negative acting photoresists has become a integral part of device fabrication strategy. In this paper we will. discuss a phenolic based photoresist which incorporates a crosslinkable resin and an acid generating sensitizer. When exposed and thermally treated, the resist forms a negative tone image which is developable in an alkaline medium. We will discuss the materials, processes and results from photon, electron and X-ray lithographic evaluations.

Investigation into the origin of microbridging in chemically amplified negative-tone photoresists

Microbridge formation in a CAMN photoresist we have developed is dependent on the ratio of dose to print (DTP) to dose to gel (DTG) as well as resist contrast. Photoresists formulated with poly(p-hydroxystyrene) (PHS) have a very high tendency to form microbridges when developed in 2.38 wt% TMAH due to high contrast and high DTP/DTG ratio. When photoresists formulated from PHS were developed in 1.2 wt% TMAH contrast and DTP/DTG ratio were reduced resulting in microbridging being nearly eliminated. Using this observation we developed an I-line CAMN photoresist with PHS type thermal stability and high resolution capabilities which can be developed in industry standard 2.38 wt% TMAH.

Improved reflectivity control of APEX-E positive tone deep-UV photoresist

A study optimizing the actinic absorbance of APEX-E positive deep UV photoresist was performed using a variety of dye additives. The selection of a dye and the optimization of dye content for APEX-E positive photoresist has led to substantial process enhancements in reduction of reflective notching and of thin film interference effects. The usual side effects as found in dyed I- line resists such as significant loss of photospeed, decreased focus latitude and sidewall angle decrease were not apparent with selected conjugated aromatic dyes. The benefit of added absorbance has allowed the direct use of dyed APEX-E to counteract the step interference (notching) problems over the severe topography of CMOS gate level and eliminate the reflective notching of surface strap level in the fabrication of 16 Mb devices. In addition, the depth of focus window was enhanced and process latitude was maintained. Geometries of 250nm were printed, with dyed APEX-E for optical densities ranging from 0.4 to 0.8 per micron with a DUV optical scanner.

TAR processing for CD control in I-line and 248-nm lithography

The combination of dyed photoresist and top antireflection (TAR) coatings was applied to I- line and deep-UV lithography on polysilicon. Optimization of the resist layers absorption and application of the TAR process significantly improves CD control of submicron gate level lithography.

INR negative resist: a negative-tone I-line chemically amplified photoresist

INR, an I-line negative photoresist, is described. Acid catalyzed cross-linking of phenolic resins using a non-metallic photoacid generator, 2,6-bishydroxymethyl-p-cresol as a cross- linker, and 9-anthracene methanol as an I-line sensitizer results in a very high photospeed aqueous TMAH developable photoresist. Poly(p-hydroxystyrene) was found to have advantages over novolac resins for formulation of high performance negative I-line photoresist. Advantages obtained by using PHS rather than novolac include higher thermal stability, elimination of undercut on nuleophilic surfaces and compatibility with 2.38 percent TMAH puddle develop processes. A high resolution version, INR-X, is described. Resolution to 0.30 micrometers and linearity to 0.35 micrometers was obtained using a 0.54NA ASML I-line stepper. 0.35 micrometers line-spaces arrays had 1.2 micrometers depth of focus and 0.40 micrometers line-space arrays had a depth of focus greater than 1.6 micrometers . An unusual characteristic found in INR-X is a very low sensitivity to variation in PEB temperature. A 3nm/ degree(s)C line-width dependency was found.