DSA Etch Status & challenges

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Sep 22, 2016 - Post-Litho. Post-trim. Post-strip. Post-BCP coat/anneal. 3X multiplication. Motivation. • To improve etch selectivity. • To improve line roughness.
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PATTERN TRANSFER CHALLENGES OF THE SEQUENTIAL INFILTRATION SYNTHESIS (SIS) OF DIRECTED SELFASSEMBLY (DSA) FOR LINE/SPACE APPLICATIONS BT CHAN / A. SINGH / V. LUONG / D. PARNELL / R. GRONHEID / JF DE MARNEFFE / D. PIUMI 22/09/2016

LINE (CHEMO-EPITAXY DSA)  

LiNe = Chemo-epitaxy Directed Self-Assembly with x-PS pinning guide. BCP = PS-b-PMMA [poly(styrene-block-methyl methacrylate)]



Post-Litho.







 Post-trim

ERPS < ERPMMA

LiNe flow

 3X multiplication



Post-strip



x-PS guide pin

Motivation • To improve etch selectivity • To improve line roughness

Post-BCP coat/anneal

BCP L0 = 28nm BT Chan et al. [MNE 2014] 2

BT. Chan / Sept. 2016

CONFIDENTIAL

SIS (SEQUENTIAL INFILTRATION SYNTHESIS) 

We introduced the S.I.S process to infiltrate the AlOx into the PMMA domain. Thus, the etch selectivity increased. At the same time, we inverse the patterning.

LiNe flow

SIS Cycling ERPS >> ERAlOx-PMMA

x-PS guide pin Arjun Singh / BT Chan et al. [SPIE 2015]

Pattern inversion

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BT. Chan / Sept. 2016

CONFIDENTIAL

PS removal (full wafer processing)

PROBLEM IN PATTERN TRANSFER 



Demonstrated AlOx lines transfer to Si3N4, but the AlOx lines toppling during the subsequent silicon substrate etch

Observed 3-AlOx lines grouping lead to pitch-walking issue especially after Si3N4 etch PS removal

SiN etch

Si3N4 etch Pitchwalking Si etch

Si etch AlOx lines toppling AlOx strip (wet)

BT Chan et al. [DSA Symposium 2015]

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BT. Chan / Sept. 2016

CONFIDENTIAL

1ST

Pitch-walking  • BCP film thickness; • PS etch times

STEP: PS REMOVAL 



We introduced Ar/O2 chemistry for PS removal etch. Unfortunately, pitch-walking appeared when we over-etched the PS domains. This is severe when the BCP film thickness is thinner. The Ar/O2 process give lollipop (undercutting) structure.

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BT. Chan / Sept. 2016

CONFIDENTIAL

POST-SIN ETCH: IMPACT OF BCP FILM THK. 

Thinner BCP film is preferable

PS removal = 40s

PS removal = 50s

Pitch-walking  • Si3N4 etch

All wafers received 6x SIS treatment

PS removal = 60s

PS removal = 70s

PS removal = 80s

PS removal = 90s

28nm

35nm

• Cannot transfer AlOx lines into Si3N4. • Line roughness increased

45nm

* D12 was 60s PS removal on full wafer. 6

BT. Chan / Sept. 2016

CONFIDENTIAL

POST-SIN ETCH: IMPACT OF SIS CYCLES 

Pattern transfer into Si3N4 is feasible without AlOx BT etch, that implied no infiltration in neutral (brush) layer.

PS removal = 40s

PS removal = 50s All wafers has 35nm BCP film thickness

3 cycles

• Pattern transfer into SiN • Pitch-walking issue

PS removal = 60s

PS removal = 70s

Higher SIS cycle, roughness  PS removal = 80s

PS removal = 90s

6 cycles

9 cycles

7

BT. Chan / Sept. 2016

CONFIDENTIAL

DSA-SIS PATTERN TRANSFER X-PS pinning

Post-SIS treatment

x-PS pinning guide

LiNe flow

When the pitch-walking start?? • • •

Over-etch at PS removal step Over-etch at AlOx Breakthrough (BT) step Si3N4 etch

How deep AlOx can diffuse into PMMA domain?

Root cause?? • • • Pitch-walking issue

x-PS-footing BCP film thickness SIS diffusion depth (loading of SIS process) 8

BT. Chan / Sept. 2016

CONFIDENTIAL

NUL (Hydroxyl-terminated poly(styrene-random-methyl methacrylate) brush, P(S-r-MMA)-OH) will be infiltrated with AlOx

TEM ANALYSIS

D08: (28nm BCP / 6 SIS cycles) D16: (35nm BCP / 9 SIS cycles) D20*: (45nm BCP / 6 SIS cycles)

PS removal X-TEM courtesy of TTCA AlOx-PMMA

D16

D20

D16

Extended PS etch times

Post-SIS

PS

Al – Blue N – Red C - Green

X-PS Si3N4

AlOx infiltrate at the top surface of the neutral layer X-TEM courtesy of Daniel Fishman and Alex Oginets of Intel Fab28

Pitch-walking  • AlOx diffusion “depth” 9

CONFIDENTIAL

ORIGIN OF THE PITCH-WALKING  

Pitch-walking became severe especially after the AlOx Breakthrough (BT) and Si3N4 etch. One of the main factors that we identified was the impact of the AlOx SIS diffusion depth into the PMMA domain.

Si3N4 layer open

As we noticed, higher the SIS diffusion depth (loading) will eventually increase the risk of the pitch-walking issue PostSIS

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BT. Chan / Sept. 2016

CONFIDENTIAL

STEP-BY-STEPS 





By careful optimization on the SIS loading, we could eliminate the pitch-walking during the pattern transfer. However, we did observe the 1-2nm CD bias due to the pitch-walking We can strip the AlOx by BCl3 plasma or wet etch (TMAH or APM).

Initial

40s PS removal

15s AlOx BT

35s SiN

30s dry AlOx removal

20s Si etch

Ar/O2

Cl2/O2/He

CF4/CHF3/O2

BCl3

HBr/SF6/O2

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BT. Chan / Sept. 2016

CONFIDENTIAL

NEW APPROACH IS NEEDED 

We need to find a new solution to:  



Drawbacks / limitations with current x-PS guiding DSA LiNe flow approach.  





mitigate the pitch-walking issue during pattern transfer. establish an integration friendly approach for future technology node

Pattern transfer: susceptible to pitch-walking issue x-PS under-layer:  Coating incompatibility with SoG liked hardmask  Poor stack reflectivity when used with standard hardmasks. 13nm Si3N4 hardmask:  it was not a planarizing layer, and  can only achieve low stack reflectivity when deposited directly on silicon substrate

x-PMMA under-layer offer better reflectivity and compatible with SoG liked hardmask. 12

BT. Chan / Sept. 2016

CONFIDENTIAL

DSA-SIS INTEGRATION FRIENDLY SOLUTION X-PMMA pinning

LiNe flow

Post-SIS treatment

x-PMMA pinning guide

X-PMMA

x-PS pinning guide

PMMA

X-PS pinning

Pitch-walking issue

13

BT. Chan / Sept. 2016

CONFIDENTIAL

PS REMOVAL 

Extended the PS removal etch, did not lead to pitch-walking issue.

40s Ar/O2

60s Ar/O2

14

80s Ar/O2

BT. Chan / Sept. 2016

CONFIDENTIAL

STEP-BY-STEPS 

AlOx removal after SoG etch is essential to reduce the aspect ratio and prevent pattern collapse.



AlOx lines pattern transfer into the silicon substrate successfully.

60s PS removal

15s AlOx BT

35s SoG

Ar/O2

Cl2/O2/He

CF4/CHF3/C4F8/O2

TMAH strip

15

60s SoC etch

20s Si etch

N2/H2

HBr/SF6/O2

BT. Chan / Sept. 2016

CONFIDENTIAL

CONCLUSIONS 

Proof of concept for the pattern transfer with both guiding systems.



x-PS guide pinning 



Reduced the pitch-walking, main focus on the SIS loading optimization

x-PMMA guide pinning 



X-PMMA pinning

X-PS pinning

Demonstrated successful pattern transfer.

Both system demonstrate LWR = 2.7nm and LER = 2.5nm after pattern transfer into Si substrate. Presented @ SPIE 2016 16

BT. Chan / Sept. 2016

CONFIDENTIAL

ACKNOWLEDGEMENTS 

DSA Group  



Nadia Vandenbroeck Hari Pathangi

Material suppliers   



ASM International  



Merck JSR BSI

Werner Knaepen Jan Willem Maes

TEL Technology Center, America LLC, Technical Support, Etch Group  

Fumiko Yamashita Kaushik Kumar



XSEM support team



Intel   

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Safak Sayan Taisir Marzook Daniel Fishman / Alex Oginets (F28)

BT. Chan / Sept. 2016

CONFIDENTIAL

Thank you