Tatsuhiko Ema

Patterning strategy and performance of 1.3NA tool for 32nm node lithography

We have designed the lithography process for 32nm node logic devices under the 1.3NA single exposure conditions. The simulation and experimental results indicate that the minimum pitches should be determined as 100nm for line pattern and 120nm for contact hole pattern, respectively. The isolated feature needs SRAF to pull up the DOF margin. High density SRAM cell with 0.15um2 area is clearly resolved across exposure and focus window. The 1.3NA scanner has sufficient focus and overlay stability. There is no immersion induced defects.

Immersion resist process for 32-nm node logic devices

Key issues of resist process design for 32nm node logic device were discussed in this paper. One of them is reflectivity control in higher 1.3NA regime. The spec for the reflectivity control is more and more severe as technology node advances. The target of reflectivity control over existent substrate thickness variation is 0.4%, which was estimated from our dose budget analysis. Then, single BARC process or stacked mask process (SMAP) was selected to each of the critical layers according to the substrate transparency. Another key issue in terms of material process was described in this paper, that is spin-on-carbon (SOC) pattern deformation during substrate etch process. New SOC material without any deformation during etch process was successfully developed for 32nm node stacked mask process (SMAP). 1.3NA immersion lithography and pattern transfer performance using single BARC

Performance of immersion lithography for 45-nm-node CMOS and ultra-high density SRAM with 0.25um2

Immersion lithography was applied to 45nm node logic and 0.25um2 ultra-high density SRAM. The predictable enhancement of focus margin and resolution were obtained for all levels which were exposed by immersion tool. In particular, the immersion lithography enabled to apply the attenuating phase shift mask to the gate level. The enough lithography margin for the alternating phase shift mask was also obtained by using not only immersion tool but also dry tool for gate level. The immersion lithography shrunk the minimum hole pitch from 160nm to 140nm. Thus, the design rule for 45nm node became available by using immersion lithography.

Patterning performance of hyper NA immersion lithography for 32nm node logic process

We have developed the lithography process for 32nm node logic devices under the 1.35NA single-exposure conditions. In low-k1 generation, we have to consider the minimum pitch resolution and two-dimensional pattern fidelity at the same time. Although strong RET (Resonance Enhancement Technique) can achieve the high image contrast, it has negative effects like line end shortening and resist pattern collapse. Moderate RET such as annular illumination can combine the minimum pitch resolution and two-dimensional pattern fidelity with hyper NA illumination condition. The simulation and experimental results indicate that the minimum pitches should be determined as 100nm for line pattern and 110nm for contact hole pattern, respectively. The isolated contact hole needs SRAF and focus drift exposure to improve DOF. Embedded SRAM cell of 0.125&mgr;m2 area is clearly resolved across exposure and focus window.

CD and defect improvement challenges for immersion processes

The intention of this study is to develop an immersion lithography process using advanced track solutions to achieve world class critical dimension (CD) and defectivity performance in a state of the art manufacturing facility. This study looks at three important topics for immersion lithography: defectivity, CD control, and wafer backside contamination. The topic of defectivity is addressed through optimization of coat, develop, and rinse processes as well as implementation of soak steps and bevel cleaning as part of a comprehensive defect solution. Develop and rinse processing techniques are especially important in the effort to achieve a zero defect solution. Improved CD control is achieved using a biased hot plate (BHP) equipped with an electrostatic chuck. This electrostatic chuck BHP (eBHP) is not only able to operate at a very uniform temperature, but it also allows the user to bias the post exposure bake (PEB) temperature profile to compensate for systematic within-wafer (WiW) CD non-uniformities. Optimized CD results, pre and post etch, are presented for production wafers. Wafer backside particles can cause focus spots on an individual wafer or migrate to the exposure tools wafer stage and cause problems for a multitude of wafers. A basic evaluation of the cleaning efficiency of a backside scrubber unit located on the track was performed as a precursor to a future study examining the impact of wafer backside condition on scanner focus errors as well as defectivity in an immersion scanner.

Performances of Novel Nozzle-Scan Coating Method

A novel nozzle-scan coating (NS-coating) method is useful for reducing the coated volume and its cost. We define the (waste-fluid rate) WFR as the ratio of the waste fluid to the fluid supplied on the wafer. In conventional spin-coating, the WFR is about 1500%. In the case of the extrusion-spin coating, the WFR decreases to 203%. But using the NS-coating with low speed and large acceleration, the WFR of the raw materials drastically decreased to 30%. This paper introduces some lithographic performances of NS-coating film of KrF chemical amplified resist that was coated with low WFR condition.

Feasibility of Ultra-Low k1 Lithography for 28nm CMOS Node

We have designed the lithography process for 28nm node logic devices using 1.35NA scanner. In the 28nm node, we face on the ultra-low k1 lithography in which dense pattern is affected by the mask topography effect and the oblique-incidence. Using the rigorous lithography simulation considering the electro-magnetic field, we have estimated accurately the feasibility of resolution of the minimum pitch required in 28nm node. The optimum mask plate and illumination conditions have been decided by simulation. The experimental results for 28nm node show that the minimum pitch patterns and minimum SRAM cell are clearly resolved by single exposure.

Resist process control for 32-nm logic node and beyond with NA > 1.30 immersion exposure tool

Resist process challenges for 32-nm node and beyond are discussed in this paper. For line and space (L/S) logic patterns, we examine ways to balance the requirements of resolution-enhancement techniques (RETs). In 32-nm node logic patterning, two-dimensional (2D) layout pattern deformation becomes more severe with stronger RET (e.g., narrow angle CQUAD illumination). Also pattern collapse more frequently happens in 2D-pattern layouts when stronger RET is used. In contrast, milder RET (annular illumination) does not induce the severe pattern collapse in 2D-pattern layout. For 2D-pattern layouts, stronger RET seems to worsen image contrast and results in high background-light in the resist pattern, which induces more pattern collapse. For the minimum-pitch L/S pattern in 32-nm node logic, annular illumination is acceptable for patterning with NA1.35 scanner when high contrast resist is used. For contact/via patterns, it is necessary to expand the overlapping CD process window. Better process margin is realized through the combination of hole-shrink technique and precise acid-diffusion control in an ArF chemically amplified resist.