Scott L. Light

A comparison of the pattern transfer of line-space patterns from graphoepitaxial and chemoepitaxial block co-polymer directed self-assembly

Block co-polymer directed self-assembly (BCP DSA) has become an area of fervent research activity as a potential alternative or adjunct to EUV lithography or self-aligned pitch multiplication strategies. This presentation will evaluate two DSA strategies for patterning line-space arrays at 30nm pitch: graphoepitaxial DSA with surface-parallel cylinder BCPs and chemoepitaxial DSA with surface-normal lamellar BCPs. A comparison of pattern transfer into hard-mask and substrate films will be made by consideration of line and space CDs, line profile of cross-sectional SEM images, and comparison of relative LWR/SWR. The processes will be benchmarked against Micron’s process used in manufacturing its 16nm half-pitch NAND part.

Simulation-based pattern matching using scanner metrology and design data to reduce reliance on CD metrology

Scanner matching based on wafer data has proven to be successful in the past years, but its adoption into production has been hampered by the significant time and cost overhead involved in obtaining large amounts of statistically precise wafer CD data. In this work, we explore the possibility of optical model based scanner matching that maximizes the use of scanner metrology and design data and minimizes the reliance on wafer CD metrology. A case study was conducted to match an ASML ArF immersion scanner to an ArF dry scanner for a 6Xnm technology node. We used the traditional, resist model based matching method calibrated with extensive wafer CD measurements and derived a baseline scanner manipulator adjustment recipe. We then compared this baseline scanner-matching recipe to two other recipes that were obtained from the new, optical model based matching method. In the following sections, we describe the implementation of both methods, provide their predicted and actual improvements after matching, and compare the ratio of performance to the workload of the methods. The paper concludes with a set of recommendations on the relative merits of each method for a variety of use cases.

A study on the automation of scanner matching

Scanner matching based on CD or patterning contours has been demonstrated in past works. All of these published works require extensive wafer metrology. In contrast, this work extends a previously proposed optical pattern matching method that requires little metrology by adding the component requirements and the procedure for creating an automation flow. In a test case, we matched an ASML XT:1900i using a DOE to an ASML NXT:1950i scanner using FlexRay. The matching was conducted on a 4x nm process test layer as a development vehicle for the 2x nm product nodes. The paper summarizes the before and after matching data and analysis, with future opportunities for improvements suggested.

A methodology for the characterization of topography induced immersion bubble defects

A key issue regarding the introduction of 193nm immersion lithography into production is immersion specific defects. One of these new defect types is the formation of air bubbles in the immersion fluid near or on the resist surface, which can then cause significant local dose variations. One possible mechanism for inducing bubble formation is the introduction of surface topography, such as seen on a typical product wafer, which could then disrupt the immersion fluid flow and entrain air. This brings up the question of what, if any, types of topography we need to be worried about and how do we test all the possible variants that will exist on product wafers. To help address this issue we have created a special topography reticle and wafer set and used them for exposures on a prototype immersion scanner. The wafer set was generated using a first level reticle designed to have an extremely wide range of topography types in a modular and systematically varying format. The wafer fabrication included skews of the trench depths, variation of the surface contact angle by using different topcoats, and optimization of the process flow to enable high contrast defect inspections. The second level reticle used for the immersion exposures was designed to cover the entire topography wafer with dose sensitive grating structures to detect any dose modulation caused by bubbles. In this paper we present the design of these reticles and wafers and the results of the first immersion exposures. Flat, unpatterned wafers were also exposed on the immersion tool in order to provide a basis for comparison. A KLA 2351 inspection tool was used to inspect all the wafers for defects. The initial results of these tests did not show a strong interaction of bubbles with topography.

Graphoepitaxial and chemoepitaxial methods for creating line-space patterns at 33nm pitch: comparison to a HVM process

Block copolymer directed self-assembly (BCP-DSA) may provide a less costly method of forming sub-38nm pitch line-space patterns relative to proven HVM methods, but DSA needs to provide equivalent or improved defect density and pattern quality to warrant consideration for displacing current HVM methods. This paper evaluates the process constraints of three DSA flows and compares the pattern quality after pattern transfer for each flow at its optimal process conditions to the same pattern created by a proven HVM process flow.

Resist freezing process challenges of cross pattern applications

Three resist freezing methods (fluoride plasma, chemical and thermal freezing) were studied for double patterning cross pattern by printing the second layer directly on top of the first resist layer. Different methods show different challenges: plasma freezing is very hard to remove footing on both layers; Chemical freezing first layer CD will grow after completion of second pattern; thermal freezing will change line curvature when the CD is smaller than 50nm, if first layer is wave type pattern.

Wafer quality analysis of various scribe line mark designs

Scribe Line Marks (SLM) printed on substrates are a standard method used by modern scanners for wafer alignment. Light reflected from the SLM forms a diffraction pattern which is used to determine the exact position of the wafer. The signal strength of the diffraction order needs to reach a certain threshold for the scanner to detect it. The marks are changed as the wafers go through various processes and are buried underneath complex film stacks. These processes and stacks can severely reduce wafer quality (WQ). Equipment manufactures recommend several variations of the SLM to improve WQ but these variations are not effective for certain advanced processes. This paper discusses theoretical analysis of how SLM designs affect wafer quality, addresses the challenge of self-aligned double patterning (SADP) on SLMs and experimentally verifies results using various structures.

Improving aberration control with application specific optimization using computational lithography

As the industry drives to lower k1 imaging we commonly accept the use of higher NA imaging and advanced illumination conditions. The advent of this technology shift has given rise to very exotic pupil spread functions that have some areas of high thermal energy density creating new modeling and control challenges. Modern scanners are equipped with advanced lens manipulators that introduce controlled adjustments of the lens elements to counteract the lens aberrations existing in the system. However, there are some specific non-correctable aberration modes that are detrimental to important structures. In this paper, we introduce a methodology for minimizing the impact of aberrations for specific designs at hand. We employ computational lithography to analyze the design being imaged, and then devise a lens manipulator control scheme aimed at optimizing the aberration level for the specific design. The optimization scheme does not minimize the overall aberration, but directs the aberration control to optimize the imaging performance, such as CD control or process window, for the target design. Through computational lithography, we can identify the aberration modes that are most detrimental to the design, and also correlations between imaging responses of independent aberration modes. Then an optimization algorithm is applied to determine how to use the lens manipulators to drive the aberrations modes to levels that are best for the specified imaging performance metric achievable with the tool. We show an example where this method is applied to an aggressive memory device imaged with an advanced ArF scanner. We demonstrate with both simulation and experimental data that this application specific tool optimization successfully compensated for the thermal induced aberrations dynamically, improving the imaging performance consistently through the lot.

Effects of reticle birefringence on 193nm lithography

Unpolarized light has traditionally been used for photolithography. However, polarized light can improve contrast and exposure latitudes at high numerical aperture (NA), especially for immersion lithography with an NA > 1.0. As polarized light passes through a reticle, any birefringence (BR) in the reticle material can cause a change in the orientation or degree of polarization, reducing the contrast in the final resist image. This paper shows the effects of reticle BR on dry and immersion imaging for 193nm lithography. The BR magnitude and orientation of the fast axis were mapped across several unpatterned mask blanks, covering a range of BR from 0 to 10 nm/cm. These reticles were printed with a series of open areas surrounded by test structures. The BR was measured again on the patterned reticles, and several locations were selected to cover a range of magnitudes at different orientations of the fast axis. Dry and immersion imaging were evaluated, looking at BR effects on dense lines and contact structures. Mask error enhancement factor (MEEF), line edge roughness (LER), and dose and focus latitudes were studied on line/space patterns. Dose and focus latitudes and 2-D effects were studied on contact patterns. Based upon these results, the effect of reticle BR on CD is minimal, even for BR values up to 10 nm/cm.

Fundamental characterization of shrink techniques on negative tone development based dense contact holes

Enormous advances have been made in recent years to design sub 40nm dense contact hole pattern with local CD uniformity (CDU) that the process can tolerate. Negative tone development process (NTD) on 193nm photoresists has achieved this to a large extent without the requirement of additional processing steps on the patterned layer. With further shrinking of size of the subsequent nodes, the demand to produce smaller patterns with wider process window, low defectivity, and improved CDU is increasing, and reaching beyond what can be achieved through NTD alone. A number of techniques are in practice today to achieve this, most notably, implementation of a collar of Atomic Layer Deposited SiO2 (ALD) on photoresist or substrate. However, in recent years, various material suppliers have also proposed shrink chemistries to achieve this. In this paper, we have provided fundamental characterization of shrink via application of spin-on agents (organic as well as aqueous) on the post-imaged pattern. We have also compared them for their shrink capacity, defect tendency, dry etch capability and ease of implementation in the process flow. In addition, we have provided recommendations on which technique is suitable for a given set of process prerequisites.