KEYWORDS: Back end of line, Dielectrics, Etching, Lithography, Reactive ion etching, Photoresist materials, Optical lithography, Semiconducting wafers, Copper, Polishing
A novel back-end-of-line (BEOL) patterning and integration process termed Multi-Level Multiple Exposure
(MLME) technique is herein introduced. The MLME technique simplifies BEOL dual damascene (DD) integration while
simultaneously being applicable to all BEOL levels. It offers a patterning resolution reaching into the sub-100nm region
and improves semiconductor manufacturing cost and throughput. MLME employs a dual-layer imaging stack (via + trench resists) cast onto a customized etch transfer multilayer stack. This process implements a strict litho-litho-etch sequence for transferring the trench- and via-patterns into the dielectric layer. Under the MLME scheme, two imaging
steps (i.e. via- and trench-level patterning) are executed consecutively followed by a dry etch process that transfers the
lithographically-formed patterns into the customized etch transfer multilayer stack and further into the dielectric layer.
The MLME integration scheme not only decreases the number of overall process steps for the full DD BEOL process but
also eliminates several inter-tool wafer exchange sequences as performed in a conventional litho-etch-litho-etch process
flow. All MLME process steps were demonstrated i.e. combined 193nm-dry dual-resist layer MLME via- and trench-lithography,
full pattern transfer of via- and trench-patterns into the dielectric layer using reactive ion etching (RIE), as
well as electroplating and polishing of the DD patterns. This paper provides a detailed description of both post-lithography
steps of the DD process for a DD BEOL structure, i.e. (i) the RIE-pattern transfer process with the customized multilayer stack, and (ii) the metallization process completing the DD process for one BEOL layer.
Furthermore, the integration capabilities of the MLME technique were demonstrated and characterized by generating an
electrically functional via-chain connecting two neighboring BEOL layers fabricated by subsequently applying the MLME approach to both layers. An exhaustive description and evaluation of MLME lithographic patterning is given in an accompanying paper.
KEYWORDS: Optical lithography, Einsteinium, Back end of line, Etching, Dielectrics, Semiconducting wafers, Lithography, Photoresist materials, Nanoimprint lithography, Reactive ion etching
In this work, the conventional via-first dual damascene (DD) patterning scheme is replaced by a cost-efficient
Multi-Level Multiple Exposure (MLME) patterning and etching approach. A two-layer positive-tone photoresist stack is
sequentially imaged using 193 nm dry lithography, to produce a DD resist structure that is subsequently transferred into
an auxiliary dual organic underlayer stack, and then further into a dielectric layer. This novel integration approach
eliminates inter-tool wafer exchange sequences as performed in a conventional litho-etch-litho-etch process flow, while
simultaneously being applicable to all back-end-of-the-line (BEOL) levels, ensuring throughput increase. The top and
bottom resist layers are chemically designed in such a way that they feature differential solubility in organic solvents
making it possible to coat the top photoresist onto the bottom resist layer without intermixing to enable a strict litholitho-
etch processing sequence. Independent registration of the via and trench structures in the bottom and top resist
layers is achieved by selective photospeed decoupling of the respective layers, so that the bottom resist is largely
insensitive at nominal resist exposure dose for the top resist. Imaging performance evaluation of the newly introduced
MLME technology includes the resist materials selection process and their required properties (solvent compatibility,
adhesion, photospeed, defectivity and correction of via dose bias due to trench exposure) as well as metrology work.
Image transfer of the patterned DD resist structure into an underlying transfer layer stack and then further into a
dielectric layer using Reactive Ion Etching (RIE) followed by electroplating, polishing and electrical testing was also
thoroughly investigated and is described in detail in an accompanying paper.
KEYWORDS: Lithography, Etching, Photomasks, Semiconducting wafers, Metals, Critical dimension metrology, Silicon, Image processing, Back end of line, Finite element methods
This paper will present results obtained during the early development of a lithography process to meet the requirements of the 65 nm node in the BEOL. For the metal levels, an IBM/JSR jointly developed trench level resist was characterized and implemented. Resist image profile, process window, through pitch performance, image shortening and the effect of illumination conditions are discussed. Results from focus - exposure monitor (FEM) wafers are shown which were characterized for minimum resolution, process window and electrical continuity through a maze structure. For the via levels, results from another IBM/JSR jointly developed resist with high resolution and process windows are described. Process windows for nested and isolated vias are given, as well as results showing the improvement in process window and resolution due to the ARC etch. The results also include FEM measurements showing the electrical continuity through simple via chain structures versus the dimension of the via.
This paper presents data obtained in developing a lithography process for the metal and via levels using a first generation 193 nm stepper and first generation 193 nm photoresist. For the line/space levels, process windows obtained using chrome on glass (COG) and phase shift masks are presented. The effect of print bias (wafer - mask dimension) on process window is shown. At 280 nm pitch, process windows for COG and phase shift masks are compared. When using a phase shift mask to print 245 nm pitch, thinner resist is shown to increase the process window. Results are shown for printing 245 nm pitch with a COG mask. For contact hole and via levels, a resist reflow process was investigated with the same resist used for the line/space levels. In this process contact holes are printed larger than required and then reduced in size by heating the resist and causing it to flow. The results obtained with different mask dimensions and different wafer critical dimension (CD) targets are discussed. Results show that a process could be developed for printing 150 nm contact holes with 400 nm depth of focus at 5% exposure latitude. Finally, the through-pitch behavior as a function of reflow bake temperature is shown. Although the more isolated vias tend to show more shrinkage than the nested vias, it is shown that the deviation in size through pitch can be controlled by adjusting the mask dimension.
Several contact hole shrinking techniques have been discussed in the literature recently. Two notable techniques; Resolution Enhancement Lithography Assisted by Chemical Shrink (RELACSTM) and Resist Flow Process (RFP) were investigated in conjunction with several commercially available high activation energy chemically amplified materials and one bilayer material. During the course of this study the unique set of advantages along with the inconveniences associated with each technique were explored. It was not only the lithographic attributes of each technique that were of interest, but also characteristics that would effect manufacturability. To that end, experiments were designed so that standard statistical techniques could be employed at the data analysis stage. The attributes of interest were the amount and control of shrinkage, nested and isolated feature bias, process window comparisons, and line edge roughness. It will be shown how several of theses attributes are directly related to manufacturing issues such as lot-to-lot repeatability and linewidth variations across the wafer.
This paper presents data obtained in developing a process using 193 nm lithography and the RELACS contact hole shrink technique. For the line/space levels, process windows showing resist performance using chrome on glass masks are presented. Data showing feature size linearity and the requirements for optical proximity correction (OPC) are presented. Some of the OPC trends observed are discussed and compared to results obtained using 248 nm lithography. Image shortening data also compares the results obtained in 193 and 248 lithography. Etch results for the new 193 resists are given and show the etch resistance of this relatively new class of photoresist materials. For contact hole and via levels, results using 193 lithography and COG masks show the importance of the mask error enhancement factor (MEEF), print bias and resolution. Due to the relative immaturity and performance of contact hole resists for 193 lithography, Clariant's RELACS process was investigated with 248 nm resists. In this process contact holes are printed larger than required and then reduced to the desired size by a chemical shrink process. Results obtained with 248 lithography using state of the art resists and phase shift masks are discussed. It was found that 140 nm contact holes with at least 0.5 micrometer depth of focus could be obtained. Cross sections and process windows are shown.
The problem of image shortening is well known in semiconductor lithography. As rectangular features decrease in width, the length of the feature will print smaller than the mask image length. This problem places a constraint upon overall device design because space must be allowed for line extensions and/or adding to the side of features. Making corrections for image shortening requires mask redesign, which increases the time and cost of new product development.
KEYWORDS: Polymers, Lithography, Data modeling, Absorbance, Deep ultraviolet, Modeling, Photography, Systems modeling, Photoresist materials, Semiconductors
The fundamental basis of resist performance in semiconductor lithography is the creation of a dissolution gradient in the resist film. For positive resists the dissolution rate (DR) and dissolution characteristics of the exposed as well as unexposed regions are important factors in determining the performance of the resist. Since the establishment of the dissolution rate curve as a method for evaluating photographic materials, many investigators have tried to correlate dissolution rate data with lithographic performance in a systematic way.
This new photoresist system extends the capability of the ESCAP platform previously discussed. (1) This resist material features a modified ESCAP type 4-hydroxystyrene-t-butyl acrylate polymer system which is capable of annealing due to the increased stability of the t-butyl ester blocking group. The resist based on this polymer system exhibits excellent delay stability and enhanced etch resistance versus previous DUV resists, APEX and UV2HS. Improved stabilization of chemically amplified photoresist images can be achieved through reduction of film volume by film densification. When the host polymer provides good thermal stability the soft bake conditions can be above or near the Tg (glass transition) temperature of the polymer. The concept of annealing (film densification) can significantly improve the environmental stability of the photoresist system. Improvements in the photoacid generator, processing conditions and overall formulation coupled with high NA (numerical aperture) exposure systems, affords linear lithography down to 0.15 micrometer for isolated lines with excellent post exposure delay stability. In this paper, we discuss the UV4 and UV5 photoresist systems based on the ESCAP materials platform. The resist based on this polymer system exhibits excellent delay stability and enhanced etch resistance versus APEX-E and UV2HS. Due to lower acrylate content, the Rmax for this system can be tuned for feature-type optimization. We demonstrate sub-0.25 micrometer process window for isolated lines using these resists on a conventional exposure tool with chrome on glass masks. We also discuss current use for various device levels including gate structures for advanced microprocessor designs. Additional data will be provided on advanced DRAM applications for 0.25 micrometer and sub-0.25 micrometer programs.
X-ray exposures performed at IBM's Advanced Lithography Facility (ALF) in Hopewell Junction, New York has led to the ability to routinely print sub 250nm discrete devices in photoresist. When fully processed, the resulting electrical channel length for these devices is below 150nm leading to average switching delays of 35 picoseconds. Sub 150nm devices with resulting electrical channel lengths of 100nm have also been made producing switching delays of 20 picoseconds, which are among the fastest reported in CMOS technology. In addition to the discrete devices, fully functional 0.25um 64Kb SRAMs were fabricated with an approximate 40 percent chip yield on the best wafer. Recent improvements in the overall lithographic process have enabled the gate line to be printed at sub 125nm. The resulting electrical channel is below 100nm. Device performance is expected to be faster at these smaller dimensions. The results obtained are based on several lots of 200mm wafers processed with the use of mix and match (x-ray to optical) steppers. The results can be viewed as current x-ray lithography in ALF.
Ronald DellaGuardia, Chet Wasik, Denise Puisto, Robert Fair, Lars Liebmann, Janet Rocque, Steven Nash, Angela Lamberti, George Collini, R. French, Ben Vampatella, George Gifford, V. Nastasi, Phil Sa, F. Volkringer, Thomas Zell, David Seeger, John Warlaumont
This paper describes results achieved from the fabrication of 64Mb DRAM chips using x-ray lithography for the gate level. Three lots were split at the gate level for exposure with either Micrascan 92 at IBM's Advanced Semiconductor Technology Center (ASTC) or x-ray at the Advanced Lithography Facility (ALF) containing a Helios super-conducting storage ring and a Suss stepper. The x-ray mask was fabricated at MMD (Microlithographic Mask Development Facility) as a two-chip mask containing one chip which had zero defects. To achieve adequate overlay performance between the x-ray exposed gate level and previous optically- printed levels, the mask was fabricated with an intentional magnification correction. The alignment scheme for both Suss and Micrascan was first order to an ASM zero level, and second order to each other. Results from the first lot show 90% of the chips tested achieved a +/- 140 nm target for the Suss to Micrascan overlay. Critical dimension control (across wafer and across chip) was measured and found to be comparable between Suss and Micrascan. Electrical performance was comparable to the optical wafers. Chips were fabricated with zero defects in many of the 1 Mb segments. There were also x-ray fabricated chips which demonstrated 63 Mb addressable bits.
Access to the requested content is limited to institutions that have purchased or subscribe to SPIE eBooks.
You are receiving this notice because your organization may not have SPIE eBooks access.*
*Shibboleth/Open Athens users─please
sign in
to access your institution's subscriptions.
To obtain this item, you may purchase the complete book in print or electronic format on
SPIE.org.
INSTITUTIONAL Select your institution to access the SPIE Digital Library.
PERSONAL Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.