Negative Tone Development (NTD) process with ArF immersion has been developed for the next generation
lithography technology because it shows good resolution performance and process window for C/H and trench patterning.
Because of the etch requirement, tri-layer process has been used popularly. However, most of the Si-HM materials are
optimized for positive tone development process and most of them show poor lithography performance in NTD process.
In this paper, we study the behaviors of Si-HM for NTD process, develop new concepts and optimize the formulation of
Si-HM to match the resist for NTD process bellow N28 node device.
In this paper we demonstrate the process of creating a large-area, extreme field of view (XFOV) SEM image of a critical
layer of an IC product, using an array of images captured with a typical, production CD-SEM. Individual CD-SEM
images, taken side-by-side over a large area were processed to create a combined extreme field of view (XFOV) image.
All feature edges were identified across this XFOV image and the edges extracted, creating feature contours. The feature
contours were then compared to design and simulation data, and differences identified.
KEYWORDS: Reflectivity, Metals, Line width roughness, Logic devices, Multilayers, Etching, Lithography, Control systems, Immersion lithography, Back end of line
Reflectivity control through angle is challenging at hyper NA, especially for Logic
devices which have various pitches in the same layer. A multilayer antireflectant system
is required to control complex reflectivity resulting from various incident angles. In our
previous works, we showed the successful optimization of multilayer antireflectant
systems at hyper NA for BEOL layers. In this paper, we show the optimization of new
multilayer bottom anti-reflectant systems to meet new process requirements at 28nm
node Logic device. During the manufacturing process, rework process is necessary when
critical dimension or overlay doesn't meet the specifications. Some substrates are
sensitive to the rework process. As a result, litho performance including the line width
roughness (LWR) could change. The optimizations have been done on various stack
options to improve LWR. An immersion tool at 1.35NA was used to perform lithography
tests. Simulation was performed using ProlithTM software.
As line width roughness (LWR) and depth of focus (DoF) become the critical lithography challenges,
there is a growing interest in applying surface conditioner solutions during post-develops process to
increase DoF and reduce LWR. Previous work1 has demonstrated that a significant LWR reduction and DoF increase can be achieved through the utilization of a surface conditioner in the features of lines/spaces patterned for 45nm node by immersion lithography. However, the previous generation surface conditioner is not able to provide effective LWR improvement for the resist pattern having
LWR less than 5nm.
In this paper, 45nm lines/spaces features, having 4.8nm LWR, were patterned using immersion lithography to evaluate a newly-formulated surface conditioner's performance on LWR reduction. The results showed there is about 20% LWR reduction and the LWR was reduced to 4nm, which indicates the newly-formulated surface conditioner is capable of doing further LWR reduction on the pattern whose LWR is less than 5nm. In addition, surface conditioners were applied to extend the capability of 193nm "dry" lithography process window below the k2 = 0.3 threshold by DoF increase. The result demonstrated there is a significant process improvement on DoF which results in a usable DoF process window in practice comparable to that of "wet" lithography process.
At the 32nm node, the most important issue for mass production in immersion lithography is defectivity control. Many methods have been studied to reduce post-exposure immersion defects. Although a topcoat process demonstrates good immersion defect prevention, a topcoat-less resist process is an attractive candidate for immersion lithography due to cost reduction from a simplified process. In this paper we took the innovative approach of chemically designing an internal self-assembling barrier material that creates a thin embedded layer which functions as a topcoat. Data will be presented on this novel self assembly concept, illustrating the control of leaching, contact angle and immersion defects. Several optimized process flows with non-topcoat resists were also studied to decrease the amount of immersion defects. This study was used to verify the capability of a topcoat-less immersion process to achieve the low-defectivity levels required for 32nm node production.
The double dipole lithography (DDL) has been proven to be one of the resolution enhancement technologies for 45 nm
node. In this paper, we have implemented a full-chip DDL process for 45nm node using ArF immersion lithography.
Immersion exposure system can effectively enlarge the process DoF (depth of focus). Combining with dipole
illumination can help us to reach smaller k1 value (~0.31) and meet the process requirements of poly and diffusion
layers on 45nm node by using only 0.93 NA exposure tool. However, from a full-chip processing point of view, the
more challenging question should be: how to calibrate a good model from two exposure and decompose original design
to separate mask sets? Does the image performance achieve a production worthy standard? At 45nm node, we are
using one-fourth of the exposure wavelength for the patterning; there is very little room for error. For DDL full-chip
processing, we need a robust application strategy to ensure a very tight CD control.
We implemented an integrated RET solution that combines DDL along with polarization, immersion system, and model
based OPC to meet full-chip manufacturing requirement. This is to be a dual-exposure mask solution for 45nm node - X-dipole exposure for vertical mask and horizontal for Y-dipole. We show a process design flow starting from the
design rule analysis, layout decomposition, model-based OPC, manufacturing reliability check, and then to the mask
data preparation. All of the work has been implemented using MaskWeaverTM geometry engine. Additionally, we
investigated printability for through-pitch line features, ASIC logic, and SRAM cell design patterns. Different circuit
layout needs dedicated special OPC treatment. To characterize the related process performance, we use mask
enhancement error factor (MEEF), process window (PW), and critical dimension uniformity (CDU) to analyze the
simulation data. Since we used the tri-tone Att-PSM, the mask making flow and spec was also taking into
consideration. The device electrical performance was examined for production feasibility. We conclude that the DDL
process is ready for 45nm node and is well within reach to be used on next generation production environment.
As lithographic technology goes beyond the 45nm node, depth of focus (DOF) and
line width roughness (LWR) for poly gates have become critical parameters. There is a
growing interest in applying surface conditioner solutions during the post-develop
process to increase DOF and reduce LWR. Surface conditioners interact with resist
sidewall selectively, causing surface plasticization effect and smoothing the sidewall
profile. As a result, the LWR can be reduced and the poor pattern profile located in the
focus marginal area due to poor image contrast will be improved so that the depth of
focus (DOF) can be increased significantly. In this paper, the features of lines/spaces
patterned for the 45nm node by immersion lithography were used to evaluate surface
conditioner performance with regards to DOF increase and LWR reduction. The results
demonstrate there is about 1.5 nm LWR reduction, as well as a significant improvement
on the process window for DOF, for which there is 37.5% increase for ISO poly gates
and 36% increase for DENSE poly gates. No negative impact on the effect of optical
proximity correction (OPC) and resist profile were observed with the new process.
In addition, etch testing was conducted to determine how much post-develop LER
reduction has been retained through etch by comparing post-etch and post-develop LER
for both baseline and surface conditioner processes.
As semiconductor process technology moves to 65nm and beyond, RET (resolution enhancement technology)
becomes more and more important, especially in low k1 processes, where it is used frequently.
Currently, in the 65nm generation, the k1 is ~0.4 on a 0.85 NA exposure tool. However, the NA improvement of the
exposure tool cannot meet the schedule of generation movement very well. Low k1 technology must be applied on next
generation processes. For the 45nm generation, a 0.93 NA exposure tool is available currently and is used to achieve the
production criteria. Because the k1 value is quite low (~0.31), using traditional methods cannot satisfy process
requirements.
For metal layers of the 45nm generation, 55nm photo-resist CD (critical dimension) patterning of 130nm pitch is a
difficult goal on a 0.93 NA exposure tool. Traditional OAI (off-axis-llumination) (annular mode) cannot provide enough
image contrast for pattern printing. Customization of illumination mode is an approach on low k1 processes. Another one
is utilizing light source polarization to achieve resolution improvement. In this paper, we introduce different approaches
on 45nm metal patterning. The RET approach (C-quad. illumination mode with polarization) can provide enough image
contrast in pattern printing to solve process issues.
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