Directed self-assembly (DSA) of block copolymers (BCP) could enable high resolution patterning beyond the
capabilities of current optical lithography methods via pitch multiplication from lower resolution primary lithographic
patterns. For example, DSA could enable dense feature production with pitches less than 80 nm from patterns generated
using 193 nm exposure tools without the need for double patterning or other schemes. According to theory, microphase
separation of diblock copolymers occurs when the critical condition that χN>10.5 is met while the pitch of the resulting
polymer features scale as ~N2/3, where χ is the Flory Huggins interaction parameter and N is the total degree of
polymerization for the diblock copolymer. In order to generate patterns with smaller pitches, N must be decreased while
maintaining a χN>10.5 to allow for phase separation. This requires utilization of polymers with higher χ values as N is decreased. Current materials, such as PS-b-PMMA, exhibit a relatively low χ value of ~0.04, which limits the practical pitch of DSA line-space patterns produced using PS-b-PMMA to approximately 20 nm. In this paper, we investigate alternative materials, namely poly(styrene)-b-poly(hydroxystyrene) (PS-b-PHOST), which exhibits a high χ value via hydrogen bonding interactions that can allow for production of sub-20nm pitch DSA patterns. In order to utilize any diblock copolymer for DSA, a neutral underlayer and a method for annealing the block copolymer are required. Here, a random copolymer, poly(styrene-co-hydroxystyrene-co-glycidyl methacrylate), is developed and reported for use as a neutral underlayer for PS-b-PHOST. Furthermore, a solvent annealing method for PS-b-PHOST is developed and
optimized using ethyl acetate to allow for uniform microphase separation of PS-b-PHOST.
As an alternative lithography technique, directed self-assembly (DSA) of block copolymers has shown to be promising
for next generation high resolution patterning. PS-b-PMMA has been widely studied for its use as a block copolymer in directed self-assembly and has demonstrated patterned features down to size scales on the order of 20 nm pitch.
However, due to the modest χ value for PS-b-PMMA (χ=0.038), this 20 nm feature pitch representes roughly the limiting capability of PS-b-PMMA. To achieve smaller pitch features, new block copolymers with higher χ values must be developed for use in DSA lithography. Here, poly(styrene)-b-poly(hydroxyehtylmethacrylate) or PS-b-PHEMS is
introduced as one possible such high χ polymer. PS-b-PHEMA with controlled Mw and PDI was successfully
synthesized via ATRP and fully characterized by NMR, GPC and FTIR. As a first demonstration of sub-20 nm pitch
capability in PS-b-PHEMA, a 15 nm pitch size lamella structure in PS-b-PHEMA is shown. PS-b-PHEMA has good
thermal stability, allowing it to be rapidly annealed thermally. PS-b-PHEMA also is shown to have improved etch
contrast between the two blocks as compared to PS-b-PMMA. The χ value for PS-b-PHEMA is estimated to be 0.37
based on experimental pitch scaling studies, which is almost 10 times of the χ value for PS-b-PMMA.
Poly(styrene)-b-poly(acrylic acid) copolymers (PS-b-PAA) was shown to be one promising material for achieving
substantially smaller pitch patterns than PS-b-PMMA while still retaining high etch contrast and application for chemoepitaxy.
Phase separation of acetone vapor annealed PS-b-PAA (Mw=16,000 g/mol with 50:50 volume ratio of PS: PAA)
on PS brush achieved a lamellar morphology with a pattern pitch size (L0) of 30 nm. However the thermal annealing of
the same PS-b-PAA generated a dramatically larger pitch size of 43 nm. SEM and GPC analysis revealed that the
intermolecular crosslinking during thermal annealing process has increased the effective N (degree of polymerization),
which suggests that even a small amount of crosslinking would lead to big pitch change. Thus, PS-b-PAA is not suitable for fast thermal annealing process as it loses pitch size control due to PAA crosslinking.
Directed self assembly (DSA) of block copolymers (BCP) could enable high resolution secondary patterning via pitch
multiplication from lower resolution primary lithographic patterns. For example, DSA could enable dense feature production at
pitches less than 20 nm from patterns generated using 193 nm exposure tools. According to theory, microphase separation of
block copolymers can only occur when the critical condition that χN>10.5 is met, where χ is the Flory Huggins interaction parameter and N is the total degree of polymerization for the block copolymer. In order to generate smaller DSA pattern pitches, the degree of polymerization of the block copolymer is reduced since this reduces the characteristic length scale for the polymer (e.g. radius of gyration). Thus, as N is reduced, the effect of this reduction on χN must be balanced by increasing χ to maintain a given level of phase separation. Currently, most DSA work has focused on the use of poly(styrene)-b-poly(methyl methacrylate) (PS-b-PMMA) copolymers whose low χ value (i.e. ~0.04) limits the practical DSA pitch using such materials to approximately 20nm. The general goal of this work has been to explore new higher χ block copolymer systems, develop DSA patterning schemes based on such materials, and test their ultimate pitch resolution. This paper discusses the synthesis and characterization of poly(styrene)-b-poly(hydroxystyrene) (PS-b-PHOST) copolymers made via nitroxide mediated radical polymerization. The formation of lamellar fingerprint structures in PS-b-PHOST using solvent annealing is demonstrated. Using this fingerprint data, initial estimates of χ for PS-b-PHOST are made which show that it appears to be at least one order of magnitude larger than the χ for PS-b-PMMA . Finally, graphoepitaxy of self-assembled lamellar structures in PS-b-PHOST is demonstrated using SU-8 guiding patterns on cross-linked neutral underlayers.
Directed self-assembly (DSA) of block copolymers is a promising technology for extending the patterning capability of
current lithographic exposure tools. For example, production of sub-40 nm pitch features using 193nm exposure
technologies is conceivably possible using DSA methods without relying on time consuming, challenging, and
expensive multiple patterning schemes. Significant recent work has focused on demonstration of the ability to produce
large areas of regular grating structures with low numbers of defects using self-assembly of poly(styrene)-b-poly(methyl
methacrylate) copolymers (PS-b-PMMA). While these recent results are promising and have shown the ability to print
pitches approaching 20 nm using DSA, the ability to advance to even smaller pitches will be dependent upon the ability
to develop new block copolymers with higher χ values and the associated alignment and block removal processes
required to achieve successful DSA with these new materials. This paper reports on work focused on identifying higher
χ block copolymers and their associated DSA processes for sub-20 nm pitch patterning. In this work, DSA using
polystyrene-b-polyacid materials has been explored. Specifically, it is shown that poly(styrene)-b-poly(acrylic acid)
copolymers (PS-b-PAA) is one promising material for achieving substantially smaller pitch patterns than those possible
with PS-b-PMMA while still utilizing simple hydrocarbon polymers. In fact, it is anticipated that much of the learning
that has been done with the PS-b-PMMA system, such as development of highly selective plasma etch block removal
procedures, can be directly leveraged or transferred to the PS-b-PAA system. Acetone vapor annealing of PS-b-PAA
(Mw=16,000 g/mol with 50:50 mole ratio of PS:PAA) and its self-assembly into a lamellar morphology is demonstrated
to generate a pattern pitch size (L0) of 21 nm. The χ value for PS-b-PAA was estimated from fingerprint pattern pitch
data to be approximately 0.18 which is roughly 4.5 times greater than the χ for PS-b-PMMA (χPS-b-PMMA ~ 0.04).
A series of new anionic PAGs, as well as PAG bound polymers designed for use in 193 nm photoresist materials have
been synthesized and characterized. These novel materials provide optical transparency at 193 nm and also etch
resistance. The fluorine substituted PAG bound polymer and PAG blend resist provided 110 nm (220 nm pitch)
line/space at 11.5, 13.0 mJ/cm2, and 80 nm isolated features at 3, 1 mJ/cm2, respectively. The LER (3&sgr;) results showed
the fluorinated PAG bound polymer have LER values 6.7 nm and 6.8 nm for isolated 80 nm and dense 110 nm lines
respectively, which were lower than the PAG Blend polymers
Substantially improved photoresist material designs, which can provide higher photosensitivity and precise critical
dimension and edge roughness control, will be required to enable the application of next generation lithography
technology to the production of future sub-65 nm node IC device generations. The development and characterization of
novel material platforms that solve the aforementioned basic problems with chemically amplified resists (CARs) is
essential and is already one of the major subjects of modern lithography research. In that regard, we have pursued
development of a variety of 193 nm and EUV CARs that contain photoacid generator (PAG) units covalently bonded
directly to the resin polymer backbone. However, the detailed structure-property relationships that result from this
direct attachment of the PAG functional group to the polymer have previously not yet been rigorously characterized. In
this work, the lithographic properties of a polymer-bound PAG CAR (GBLMA-co-EAMA-co-F4-MBS.TPS) and its
blended-PAG analog resist (GBLMA-co-EAMA blend F4-IBBS.TPS) were studied and compared. The direct
incorporation of PAG functionality into the resist polymer, where the resulting photoacid remains bound to the polymer,
showed improved photosensitivity, resolution, and lower LER as compared with the analogous blended-PAG resist.
The improved resolution and LER were expected due to the restricted photoacid diffusion and uniform PAG distribution
provided by direct incorporation of the PAG into the polymer backbone to make a single-component resist material.
The ability to load higher levels of PAG into the resist provided by this PAG incorporation into the polymer, as compared
to the low PAG concentrations attainable by traditional blending approaches, overcomes the sensitivity loss that should
result from reduction in photoacid diffusivity and concomitant smaller acid-catalytic chain lengths. In fact, the
polymer-bound PAG resist achieves a faster photospeed than the blended-PAG analog material under DUV radiation in
the case of the materials reported here while still providing all of the aforementioned improvements such as the improved
line edge roughness.
Conventional chemically amplified photoresist formulations are complex mixtures that include a protected polymer resin and a small molecule photoacid generator (PAG). The limited compatibility of the PAG with resist resin and the mobility of the small molecule additive can lead to problems including PAG phase separation, non-uniform initial PAG and photoacid distribution, and acid migration during the post-exposure baking (PEB) processes. The incorporation of PAG units into the main chain of the polymer resin is one possible method to alleviate these problems. Recently, we have investigated methacrylate based resists which incorporate novel PAG functional groups into the polymer main chain. These materials have demonstrated good resolution performance for both 193 nm and EUV exposure for sub-100 nm patterning. However, limited information is available on the effect of binding the PAG to the polymer on PAG photoreactivity and photoacid diffusivity. In this work, the photoacid generation rate constant (commonly referred to as the Dill C parameter for the PAG) of both triflate polymer-bound PAG and blended PAG photoresists based on poly(γ-butyrolactone methacrylate -co-2-ethyl-2-adamantyl methacrylate ) resists were determined by a new technique utilizing both quantitative FTIR spectroscopy and kinetic model fitting. The results indicate that the polymer-bound PAG resist has a lower photoacid generation rate constant (C=0.0122) than the blend PAG one (C=0.2647). This large difference in Dill C parameters would indicate that the sensitivity of the polymer-bound PAG resist is substantially lower than that of the analogous blended sample which is consistent with contrast curve data for these two samples.
Current resist materials suffer from a number of problems which must be addressed to allow continued scaling of memory and logic devices. The incompatibility of the photoacid generator (PAG) and the polymer matrix is addressed in this study. This incompatibility leads to lowered acid generation efficiency, non-uniform acid distribution and migration, and phase separation. These issues ultimately lead to undesirable, premature and non-uniform deprotection reactions in the chemically amplified resist. To alleviate these problems, it is proposed that PAG units be incorporated in the resist chain to make a one-component resist, rather than blending monomeric PAG with the resist polymer. Also, polymer bound PAG resists exhibit higher stability, lower outgassing, and lower line edge roughness (LER) than corresponding resists. The polymer bound PAG resists, poly (γ-butyrolactone methacrylate-co-2-ethyl-2-adamantyl methacrylate-co-PAG), were synthesized using free radical polymerization. PAG incorporated resists, as well as PAG blended resists were exposed using the 193 nm ASML 5500/9xx optical lithography system, with 0.63 NA. Exposed wafers were evaluated using SEM. The triflate PAG incorporated resists provided 110 nm (220 nm pitch) line space features, and 80 nm isolated features. The PAG blended resists provided 130 nm (260 nm pitch) line space features. The associated photospeed for the 110 nm line space features was 8.2 mJ/cm2, which is within road map standards.
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.