Hiroki Yoshikawa

Study and improvement approach to 193-nm radiation damage of attenuated phase-shift mask

The exposure tools have been advanced for finer patterns and higher throughput. However, it causes the increase of accumulation of exposure dose on mask, which induces the mask CD growth. This issue has been reported as the radiation damage and brought the low yield of device chips [1, 2, 3]. As the solution, the radiation damage can be reduced by the ultra extreme dry air in exposure tool [4]. It is difficult to adopt dry air to all exposure tool due to cost. In this work, we tried to solve the radiation damage from photomask making approach. The attenuated phase-shift mask (att. PSM) was chosen for this evaluation because its damage is severest. The test plates of att. PSM were exposed by ArF laser, and the amount of CD degradation and the composition change in damage area were investigated. By the analyses of TEM and EDX, it was confirmed that the root cause of radiation damage is oxidation of MoSi film. Therefore, the approaches from mask process and material were tried to prevent MoSi film from oxidation. As a result, the approach from mask material, especially modification of MoSi film is effective. And the characteristics of new MoSi film, such as CD performances, cross section, and cleaning durability, were compared with conventional att. PSM. These results show the characteristics of two masks are equivalent. Att. PSM with new MoSi film is promising solution to improve radiation damage.

Alternating phase-shift mask and binary mask for 45-nm node and beyond: the impact on the mask error control

For 45 nm node and beyond, the alternating phase-shift mask (alt. PSM), one of the most expected resolution enhancement technologies (RET) because of its high image contrast and small mask error enhancement factor (MEEF), and the binary mask (BIM) attract attention. Reducing CD and registration errors and defect are their critical issues. As the solution, the new blank for alt. PSM and BIM is developed. The top film of new blank is thin Cr, and the antireflection film and shielding film composed of MoSi are deposited under the Cr film. The mask CD performance is evaluated for through pitch, CD linearity, CD uniformity, global loading, resolution and pattern fidelity, and the blank performance is evaluated for optical density, reflectivity, sheet resistance, flatness and defect level. It is found that the performance of new blank is equal to or better than that of conventional blank in all items. The mask CD performance shows significant improvement. The lithography performance of new blank is confirmed by wafer printing and AIMS measurement. The full dry type alt. PSM has been used as test plate, and the test results show that new blank can almost meet the specifications of pi-0 CD difference, CD uniformity and process margin for 45 nm node. Additionally, the new blank shows the better pattern fidelity than that of conventional blank on wafer. AIMS results are almost same as wafer results except for the narrowest pattern. Considering the result above, this new blank can reduce the mask error factors of alt. PSM and BIM for 45 nm node and beyond.

High resolution mask process and substrate for 20nm and early 14nm node lithography

The lithography challenges posed by the 20 nm and 14 nm nodes continue to place strict minimum feature size requirements on photomasks. The wide spread adoption of very aggressive Optical Proximity Correction (OPC) and computational lithography techniques that are needed to maximize the lithographic process window at 20 nm and 14 nm groundrules has increased the need for sub-resolution assist features (SRAFs) down to 50 nm on the mask. In addition, the recent industry trend of migrating to use of negative tone develop and other tone inversion techniques on wafer in order to use bright field masks with better lithography process window is requiring mask makers to reduce the minimum feature size of opaque features on the reticle such as opaque SRAFs. Due to e-beam write time and pattern fidelity requirements, the increased use of bright field masks means that mask makers must focus on improving the resolution of their negative tone chemically amplified resist (NCAR) process. In this paper we will describe the development and characterization of a high resolution bright field mask process that is suitable for meeting 20 nm and early 14 nm optical lithography requirements. Work to develop and optimize use of an improved chrome hard mask material on the thin OMOG binary mask blank1 in order to resolve smaller feature sizes on the mask will be described. The improved dry etching characteristics of the new chrome hard mask material enabled the use of a very thin (down to 65 nm) NCAR resist. A comparison of the minimum feature size, linearity, and through pitch performance of different NCAR resist thicknesses will also be described. It was found that the combination of the improved mask blank and thinner NCAR could allow achievement of 50 nm opaque SRAFs on the final mask.. In addition, comparisons of the minimum feature size performance of different NCAR resist materials will be shown. A description of the optimized cleaning processes and cleaning durability of the 50 nm opaque SRAFs will be provided. Furthermore, the defect inspection results of the new high resolution mask process and substrate will be shared.

Attenuated phase-shift mask with high tolerance for 193nm radiation damage

In the semiconductor technology using the 193nm ArF excimer laser, the problem of radiation damage on photomask becomes more serious. This phenomenon is regarded as serious issue for semiconductor device fabrication. Some approaches have been tried to prevent the radiation damage. One of reports indicates that the radiation damage can be reduced by using an exposure tool with ultra clean extreme dry air [1]. However, it is difficult to adopt dry air into all exposure tools due to high cost. In our previous work, two facts were ascertained; radiation damage is caused by MoSi film oxidation, and depends on MoSi film composition [2]. In this paper, radiation damage was tried to decrease by MoSi film modification of att. PSM. MoSi film composition for PSM is optimized in consideration of cleaning durability, mask defect repair and processability. The new PSM is named AID (Anti Irradiation Damage). Radiation damage of AID PSM can be improved by 40[%] from conventional PSM. Cleaning durability can be also improved by AID PSM. The other evaluation items such as CD performance, cross section, defect level and repair, are equal between the AID PSM and conventional one. Additionally, the lithography performances by simulation of AID PSM are equivalent with that of conventional PSM. Therefore, it can be expected that there is no difficulty in converting conventional PSM into AID PSM. From these evaluation results, development of AID PSM was completed, and preparation for production is now going.

Improvement of CD variation control for attenuated phase-shift mask

As the required accuracy of the mask arises, Cr shading film thickness has been thinner gradually. CD linearity with the thinner Cr film thickness has better performance. However, it is difficult to apply thinner Cr film thickness simply under the condition of OD > 3, which is needed for wafer printing. So, we tried to develop new shading film. We adopted MoSi film, because MoSi film has almost no micro loading effect compared with Cr film. MoSi shading film with att.PSM satisfied OD > 3 at 193nm wavelength with good resist profile. But the issue was dry-etching selectivity, because shading layer material was the same of att. PSM layer material. Therefore super thin Cr etching stopper was inserted between MoSi shading layer and MoSi att.PSM layer. The mask CD performance of new blank was evaluated for CD linearity, CD through pitch, and global loading effect. This blank and mask process reduce loading effect, therefore the mask CD performance is improved remarkably. In conclusion, the mask manufacturing process margin was able to be expanded by this new blank and method, and it is expected that we can achieve the required specifications for att.PSM in 45nm node and beyond.