Reflective electron-beam lithography (REBL) employs a novel device to impress pattern information on an electron
beam. This device, the digital pattern generator (DPG), is an array of small electron reflectors, in which the reflectance
of each mirror is controlled by underlying CMOS circuitry. When illuminated by a beam of low-energy electrons, the
DPG is effectively a programmable electron-luminous image source. By switching the mirror drive circuits
appropriately, the DPG can ‘scroll’ the image of an integrated circuit pattern across its surface; and the moving electron
image, suitably demagnified, can be used to expose the resist-coated surface of a wafer or mask. This concept was first
realized in a device suitable for 45 nm lithography demonstrations. A next-generation device has been designed and is
presently nearing completion. The new version includes several advances intended to make it more suitable for
application in commercial lithography systems. We will discuss the innovations and compromises in the design of this
next-generation device. For application in commercially-practical maskless lithography at upcoming device nodes, still
more advances will be needed. Some of the directions in which this technology can be extended will be described.
This year marks the second year of the Special Section on Alternative Lithographic Technologies. Our issue features papers on emerging lithographic technologies that are potentially both cost-effective and scalable to high-volume manufacturing (HVM).
The digital pattern generator (DPG) is a complex electron-optical MEMS that pixelates the electron beam in the reflective electron beam lithography (REBL) e-beam column. It potentially enables massively parallel printing, which could make REBL competitive with optical lithography. The development of the REBL DPG, from the CMOS architecture, through the lenslet modeling and design, to the fabrication of the MEMS device, is described in detail. The imaging and printing results are also shown, which validate the pentode lenslet concept and the fabrication process.
Maskless electron beam lithography can potentially extend semiconductor manufacturing to the 10 nm logic (16 nm half
pitch) technology node and beyond. KLA-Tencor is developing Reflective Electron Beam Lithography (REBL)
technology targeting high-volume 10 nm logic node performance. REBL uses a novel multi-column wafer writing
system combined with an advanced stage architecture to enable the throughput and resolution required for a NGL
system. Using a CMOS Digital Pattern Generator (DPG) chip with over one million microlenses, the system is capable
of maskless printing of arbitrary patterns with pixel redundancy and pixel-by-pixel grayscaling at the wafer. Electrons
are generated in a flood beam via a thermionic cathode at 50-100 keV and decelerated to illuminate the DPG chip. The
DPG-modulated electron beam is then reaccelerated and demagnified 80-100x onto the wafer to be printed.
Previously, KLA-Tencor reported on the development progress of the REBL tool for maskless lithography at and below
the 10 nm logic technology node. Since that time, the REBL team has made good progress towards developing the
REBL system and DPG for direct write lithography. REBL has been successful in manufacturing a CMOS controlled
DPG chip with a stable charge drain coating and with all segments functioning. This DPG chip consists of an array of
over one million electrostatic lenslets that can be switched on or off via CMOS voltages to pattern the flood electron
beam. Testing has proven the validity of the design with regards to lenslet performance, contrast, lifetime, and pattern
scrolling. This chip has been used in the REBL demonstration platform system for lithography on a moving stage in
both PMMA and chemically amplified resist. Direct imaging of the aerial image has also been performed by magnifying
the pattern at the wafer plane via a mag stack onto a YAG imaging screen. This paper will discuss the chip design
improvements and new charge drain coating that have resulted in a functional DPG chip and will evaluate the current
chip performance on the REBL system. Print results for line/space and device test patterns at the 100nm node will be
presented.
Memristors were vertically integrated with CMOS circuits using nanoimprint lithography (NIL), making a transistor/memeristor hybrid circuit. Several planarization technologies were developed for the CMOS substrates to meet the surface planarity requirement for NIL. Accordingly, different integration schemes were developed and optimized. UV-curable NIL (UV-NIL) using a double layer spin-on resists was carried out to pattern the electrodes for memristors. This is the first demonstration of NIL on active CMOS substrates that are fabricated in a CMOS fab. Our work demonstrates that NIL is compatible with commercial IC fabrication process. It was also demonstrated that the memristors are integratable with traditional CMOS to make hybrid circuits without changing the current infrastructure in IC industry.
An integrated circuit combining imprinted, nanoscale crossbar switches with metal-oxide field effect transistors
(MOSFET) was fabricated and tested. Construction of the circuits began with fabrication of n-channel MOSFET
devices on silicon-on-insulator (SOI) substrates using CMOS compatible process techniques. To protect the FET devices
as well as provide a flat surface for subsequent nanoimprint lithography, passivation and planarization layers were
deposited. Crossbar junctions were then fabricated next to the FETs using imprint lithography to first define arrays of
parallel nanowires over which, a switchable material layer was deposited. This was followed by a second imprint proces
to construct another set of parallel wires on top of, and orthogonal to the first, to complete the nano-crossbar array with a
half pitch (hp) of 50 nm. The switchable crossbar devices were then connected to the gate of the FETs and the resulting
integrated circuit was tested using the FET as the output signal follower. This successful fabrication process serves as a
proof-of-principle demonstration and a platform for advanced CMOS/nanoscale crossbar hybrid logic circuits.
Displacement sensing and estimation (DSE) is important preprocessing task for many image-based processing systems
that extract information from multiple images. In last two years, we gained significant insight of the nature of DSE and
developed theory and algorithm framework named nanoscale displacement sensing and estimation (nDSE). We also
build procedures to apply nDSE to overlay alignment down to the nanoscale. We will introduce two basic theories:
Phase Delay Detection (PDD) and Derivatives-based Maximum Likelihood Estimation (DML) and associated DSE
algorithms, noticeably Near-Neighbor-Navigation (N-Cubed) algorithm. We presented our best nDSE experimental
result of 1 nm (1σ) while tracking 5 nm stepping. To develop nDSE-based nanoscale alignment, we introduced our
definition of displacement, alignment and pseudo-displacement. We presented both theoretical and practical procedures
to use nDSE to achieve nano-alignment down to the 10s of nano-meters and beyond. Then we compared nDSE-based
nano-alignment to other industry standard alignment method and attempt to show the substantial advantages of nDSE
based alignment in terms of cost and simplicity of the system design.
Nanoimprinting lithography was initiated as an alternative way to achieve nanoscale structures with high throughput and low cost. We have developed a UV-nanoimprint process to fabricate 34x34 crossbar circuits with a half-pitch of 50 nm (equivalent to a bit density of 10 Gbit/cm2). Our resist was of a single layer, which required fewer processing steps than any bi-layer process, but yielded high quality results. By engineering the surface energy of the substrate, we also eliminated the problem of trapped air during contact with the mold due to non-conformal contact such that it spreads the resist and expels trapped air. Resist adhesion to the gaps between features in the mold during mold separation is a challenge that becomes more severe as the pitch size shrinks. We have improved the resist adhesion to the substrate by applying a monolayer of surface linker molecule on the substrate surface. The surface linker bonded the resist to the substrate surface chemically and produced fine imprinted patterns at 30 nm hp.
Nanoimprint lithography is a contact-lithography technology invented in 1996 as a low-cost alternative to photolithography for researchers who need high resolution patterning. Initially perceived as a trailing-edge technology for low-cost device fabrication, it has been recently demonstrated to achieve sub-10 nm resolution and alignment, which equal or surpass even the most advanced photolithography today. At Hewlett-Packard, we have successfully used it to fabricate switchable molecular memory arrays with a dimension of 65 nm half pitch. Nanoimprint has been placed on the International Technology Roadmap for Semiconductors (ITRS) as a candidate for next-generation lithography (NGL) for insertion in the 32 nm node in Y2013. The switch from using light to using contact to pattern will indeed bring new challenges, the most important of which are alignment and the 1x mask/template. For alignment, one imprint tool maker has achieved alignment of +/-7 nm 3 sigma using Moire patterns. For template fabrication, the lack of OPC and other sub-resolution features produced large savings in patterning, but it is nearly cancelled out by the need for more aggressive inspection because of the smaller tolerable defect size. The two combined to make the predicted cost of nanoimprint template to be similar to photomasks for 45-nm half pitch. At 32-nm half pitch, EUVL masks do not have complicated sub-resolution features and are predicted to be cheaper than comparable nanoimprint templates provided that the former’s defect levels can be reduced to what is required for economical manufacturing. In both cases, the challenges are not insurmountable and solutions are being actively pursued. However, if nanoimprint is indeed the disruptive technology to photolithography, it needs to take its initial aim at the low-end market rather than mount a frontal challenge at semiconductor manufacturing, which is the high-margin customers that photolithography will pursue and protect at all cost. The recent development in nanotechnology will lead to the commercialization of a new class of nanoscale devices requiring a high-resolution lithographic technique that does not have all the functionalities of photolithography. This approach will provide an initial customer base for nanoimprint to develop and improve and position it to challenge photolithography in the distant future.
We have utilized the nanoimprint lithography process described this paper to fabricate a rewritable, nonvolatile memory cell with an equivalent density of 6.4 Gbits/cm2. The architecture of the circuit was based on an 8x8 crossbar structure with an active molecular layer sandwiched between the top and bottom electrodes. A liftoff process was utilized to produce the top and bottom electrodes, made of Pt/Ti bilayers. The active molecular layer was deposited by the Languir-Blodgett technique. We proposed the use of a new class of nanoimprint resist formulated by dissolving a polymer in its monomer, such as poly(benzyl methacrylate) dissolved in benzyl methacrylate (~8%/92% wt). The new resist enabled us to achieve Pt /Ti lines of 40 nm in width and 130 nm in pitch, as described in this paper. Our overall nanofabrication process has the advantages of relatively low temperature (~70°C) and pressure (~500 psi or 4.5 MPa), both of which are critical to preserving the integrity of the molecular layer.
A model has been developed to predict the cost of extreme ultraviolet lithography (EUVL) masks. The mask blank for EUVL consists of a low thermal expansion material substrate having a square photomask form factor and is coated with reflective Mo/Si multilayers. Absorber layers are deposited on the multilayer and patterned. EUVL mask patterning will use evolutionary improvements in mask patterning and repair equipment. One of the challenges in implementing EUVL is to economically fabricate multilayer-coated mask blanks with no printable defects. The model of mask cost assigns yield and time required for each of the steps in fabricating EUVL masks from purchase of a polished substrate to shipment of a patterned mask. Data from present multilayer coating processes and present mask patterning processes are used to estimate the future cost of EUVL masks. Several of the parameters that significantly influence predicted mask cost are discussed in detail. Future cost reduction of mask blanks is expected from learning on substrate fabrication, improvements in low defect multilayer coating to consistently obtain <0.005 defects cm-2, and demonstration of multilayer smoothing which reduces the printability of substrate defects. The model predicts that the price range for EUVL masks in production will be S30-40K, which is comparable to the price of complex phase shift masks needed to use optical lithography for 70 nm critical dimension patterning.
Minimizing image placement errors due to thermal distortion of the mask is a key requirement for qualifying EUV Lithography as a Next Generation Lithography (NGL). Employing Low Thermal Expansion Materials (LTEMs) for mask substrates is a viable solution for controlling mask thermal distortion and is being investigated by a wide array of researchers, tool makers, photomask suppliers, and material manufacturers. Finite element modeling has shown that an EUVL mask with a Coefficient of Thermal Expansion (CTE) of less than 20 ppb/K will meet overlay error budgets for <EQ 70 nm lithography at a throughput of 80 wafers per hour. In this paper, we describe the functional differences between today's photomask and EUVL masks; some of these differences are EUVL specific, while others are natural consequences of the shrinking critical dimension. We demonstrate that a feasible manufacturing pathway exists for Low Thermal Expansion Material (LTEM) EUVL masks by fabricating a wafer-shaped LTEM mask substrate using the same manufacturing steps as for fabricating Si wafers. The LTEM substrate was then coated with Mo/Si multilayers, patterned, and printed using the 10X Microstepper. The images were essentially indistinguishable from those images acquired from masks fabricated from high quality silicon wafers as substrates. Our observations lend further evidence that an LTEM can be used as the EUVL mask substrate material.
The mask is deemed one of the areas that require significant research and development in EUVL. Silicon wafers will be used for mask substrates for an alpha-class EUVL exposure tool due to their low-defect levels and high quality surface finish. However, silicon has a large coefficient of thermal expansion that leads to unacceptable image distortion due to absorption of EUV light. A low thermal expansion glass or glass-ceramic is likely to be required in order to meet error budgets for the 70 nm node and beyond. Since EUVL masks are used in reflection, they are coated with multilayers prior to patterning. Surface imperfections, such as polishing marks, particles, scratches, or digs, are potential nucleation sites for defects in the multilayer coating, which could result in the printed defects. Therefore we are accelerating developments in the defect reduction and surface finishing of low thermal expansion mask substrates in order to understand long-term issues in controlling printable defects, and to establish the infrastructure for supplying masks. In this paper, we explain the technical requirements for EUVL mask substrates and describe our efforts in establishing a SEMI standard for EUVL masks. We will also report on the early progress of our suppliers in producing low thermal-expansion mask substrates for our development activities.
Extreme UV Lithography (EUVL) is one of the leading candidates for the next generation lithography, which will decrease critical feature size to below 100 nm within 5 years. EUVL uses 10-14 nm light as envisioned by the EUV Limited Liability Company, a consortium formed by Intel and supported by Motorola and AMD to perform R and D work at three national laboratories. Much work has already taken place, with the first prototypical cameras operational at 13.4 nm using low energy laser plasma EUV light sources to investigate issues including the source, camera, electro- mechanical and system issues, photoresists, and of course the masks. EUV lithograph masks are fundamentally different than conventional photolithographic masks as they are reflective instead of transmissive. EUV light at 13.4 nm is rapidly absorbed by most materials, thus all light transmission within the EUVL system from source to silicon wafer, including EUV reflected from the mask, is performed by multilayer mirrors in vacuum.
Franz Himpsel, R. Treusch, I. Jimenez, Alan Jankowski, D. Sutherland, L. Terminello, C. Heske, Rupert Perera, D. Shuh, William Tong, James Underwood, J. Carlisle, T. Callcott, Jian Jun Jia, David Ederer, Dieter Gruen, Alan Krauss, D. Zuiker, Gary Doll
This is a review of the applications that various core level spectroscopies have in surface analysis. Three methods are highlighted, i.e., photoelectron spectroscopy of core level shifts (XPS or ESCA), absorption spectroscopy, and soft X-ray fluorescence. These techniques provide not only elemental analysis at surfaces, but also the chemical state of atoms and molecules in the outermost atomic layers, such as oxidation state, hybridization, and nearest neighbor bonding information. The probing depth can be adjusted in non-destructive fashion from 3 A to 300 A by detecting electrons or photons of variable energies. Advances in detectors and light sources, such as synchrotron radiation, are breaking ground for new applications, such as chemically-resolved microscopy.
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