Method for the microlithographic production of microstructured components
10802403 ยท 2020-10-13
Assignee
Inventors
Cpc classification
G03F7/70666
PHYSICS
G03F7/2022
PHYSICS
G03F7/7055
PHYSICS
International classification
Abstract
A method for the microlithographic production of microstructured components, includes: providing a wafer, to which a photoresist is applied at least partly; providing a mask having structures to be imaged; providing a projection exposure apparatus having an illumination unit and a projection lens; exposing the photoresist by projecting at least one part of the mask onto a region of the photoresist with the aid of the projection exposure apparatus; and ascertaining a deviation between a structure property of the structures produced on the exposed wafer from a predefined desired structure property. Ascertaining includes: determining at least one property of a light field used for exposing the photoresist applied to the wafer. The method further includes aftertreating the wafer on the basis of the ascertained deviation, and chemically developing the after treated wafer.
Claims
1. A method, comprising: exposing a photoresist by projecting at least one part of a mask onto a region of the photoresist using a projection exposure apparatus which comprises an illumination unit and a projection lens, thereby forming an exposed photoresist comprising structures; ascertaining a deviation of at least one structure property of the structures from a predefined desired structure property, wherein ascertaining comprises determining at least one property of a light field used to form the exposed photoresist; treating the exposed photoresist on the basis of the ascertained deviation of the at least one structure property, thereby forming a treated photoresist; and chemically developing the treated photoresist.
2. The method of claim 1, wherein the at least one structure property comprises a structure size of the structures.
3. The method of claim 1, wherein treating the exposed photoresist comprises altering a concentration of free hydrogen ions present in the photoresist after the exposing.
4. The method of claim 3, wherein altering the concentration of free hydrogen ions comprises post-exposing the photoresist with light having a wavelength deviating from an operating wavelength of the projection exposure apparatus.
5. The method of claim 4, comprising post-exposing the photoresist without using a mask.
6. The method of claim 3, wherein altering the concentration of free hydrogen ions comprises applying an acid or an acid scavenger to the photoresist.
7. The method of claim 6, wherein altering the concentration of free hydrogen ions comprises post-exposing the photoresist with light having a wavelength deviating from an operating wavelength of the projection exposure apparatus.
8. The method of claim 7, comprising post-exposing the photoresist without using a mask.
9. The method of claim 1, wherein treating the exposed photoresist comprises using a spatial resolution that is coarser than ten times an average structure size of the structures.
10. The method of claim 1, further comprising, while chemically developing the treated photoresist, modifying a temperature depending on the ascertained deviation.
11. The method of claim 1, wherein ascertaining the deviation of the at least one structure property comprises ascertaining at least one member selected from the group consisting of: a location-dependent measurement of the intensity distribution generated during illumination of the mask by the illumination unit; a location-dependent measurement of transmission properties of the projection lens; a pupil-dependent measurement of transmission properties of the projection lens; a polarization-dependent measurement of transmission properties of the projection lens; a measurement of the properties of the light source; and the measurement of the illumination of at least one pupil plane in the projection exposure apparatus.
12. The method of claim 1, wherein ascertaining the deviation of at least one structure property comprises calculating or modelling at least one member selected from the group consisting of: an intensity distribution generated by the illumination unit at the location of the mask; location-dependent transmission properties of the projection lens; pupil-dependent transmission properties the projection lens; polarization-dependent transmission properties of the projection lens; a wavefront of the projection lens; and an illumination of at least one pupil plane in the projection exposure apparatus.
13. The method of claim 1, wherein the at least one structure property comprises a structure position of the structures.
14. The method of claim 1, wherein iii) comprises an etching process.
15. The method of claim 1, wherein treating the exposed photoresist comprises heating the photoresist and moving the structures by local movement of the photoresist.
16. The method of claim 1, wherein: the at least one structure property comprises a structure size of the structures; treating the exposed photoresist comprises altering a concentration of free hydrogen ions present in the photo-resist after the exposing; and altering the concentration of free hydrogen ions comprises post-exposing the photoresist with light having a wavelength deviating from an operating wavelength of the projection exposure apparatus.
17. The method of claim 16, wherein altering the concentration of free hydrogen ions comprises post-exposing the photoresist with light having a wavelength deviating from an operating wavelength of the projection exposure apparatus.
18. The method of claim 16, wherein altering the concentration of free hydrogen ions comprises applying an acid or an acid scavenger to the photoresist.
19. A method of processing a photoresist, the method comprising: projecting at least one part of a mask onto a region of the photoresist using a projection exposure apparatus which comprises an illumination unit and a projection lens, thereby exposing the photoresist to form an exposed photoresist with structures; determining a property of a light field used for exposing the photoresist; using the determined property of the light field to ascertain a deviation of a structure property of the structures of the exposed photoresist from a predefined desired structure property; and treating the exposed photoresist on the basis of the ascertained deviation of the property.
20. The method of claim 19, further comprising, after treating the exposed photoresist, chemically developing the photoresist.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the figures:
(2)
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DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
(8) What the embodiments described below with reference to the schematic illustrations in
(9) In this case, according to the disclosure, in the respective procedure both with regard to ascertaining the deviations and with regard to correcting the ascertained deviations, a distinction is made with regard to the type of the structure properties, namely between (a) structure size and (b) structure position.
(10) In this case, the structure size is understood to mean the spatial extent or extension of the respective structures produced on the wafer, wherein the associated deviation from the desired value is also referred to as CD error (CD=Critical Dimension). Structure position is understood to mean the spatial position or location of the structures produced on the wafer, wherein the corresponding deviation from the desired structure position is also referred to as Overlay error.
(11) Hereinafter, firstly a description is given of possible embodiments of the disclosure for altering the structure size with reference to
(12) Furthermore, a description is given of embodiments for determining the structure size with reference to
(13) As far as firstly the alteration of the structure size according to the disclosure is concerned, by way of an aftertreatment of the wafer or photoresist following the actual exposure process, in a first embodiment in accordance with
(14) In this case, in a manner known per se, the abovementioned acid scavengers or Base Quenchers have the property of binding irreversibly to free hydrogen ions, as a result of which a threshold-value-dependent behavior of the photoresist (to the effect that free hydrogen ions are available for chemical reactions only above a specific light dose) is attained. Acid scavengers can be bases, in particular, since the latter can bind acids to form a salt.
(15) The addition both of acids and of acid scavengers that is possible in accordance with
(16) In a further embodiment, for altering the structure size, it is also possible to carry out a post-exposure of the photoresist with a wavelength deviating from the operating wavelength of the projection exposure apparatus. This can exploit the fact that conventional photoresist materials are generally sensitive across a wider wavelength range, such that even light having a wavelength deviating from the operating wavelength of the projection exposure apparatus can be used for the post-exposure.
(17) Merely by way of example, an arrangement of light-emitting diodes (LEDs) 31 is usable in accordance with
(18) In accordance with a further embodiment, not explicitly illustrated, light-emitting diodes 31 in accordance with
(19) The most widely used photoresists are those of the type described previously in which the absorption of a photon having an operating wavelength results in acid production just like an absorption of a photon in a certain first wavelength range that is different than the operating wavelength. US 2016/0048080 A1 discloses applying on a wafer W a layer including not just a photoresist in the actual sense but further substances capable of a reaction to light.
(20) The layer can contain, in particular, substances (photodestructive bases) that liberate acid scavengers, that is to say in particular bases, under exposure. The substances can be sensitive in particular in a second wavelength range, in which the actual photoresist releases no free acids upon exposure.
(21) In accordance with a further embodiment illustrated in
(22) In accordance with a further embodiment, the layer applied to the wafer W can contain a photosensitizer precursor. Photosensitizers are known from US 2016/0048080 A1. Upon exposure with radiation having the first operating wavelength, the photosensitizer precursor is cleaved to form a photosensitizer. Upon subsequent illumination with radiation in a third wavelength range, the photosensitizer (but not the photosensitizer precursor) leads to the production of free acid. The local density of produced acid is thus proportional to the intensity of the operating wavelength multiplied by the intensity in the third wavelength range. In one embodiment in accordance with
(23) In accordance with a further embodiment indicated schematically in
(24) As an alternative to the use of a one- and/or two-dimensional deflection device for the radiation emitted by an infrared illumination element 41, an alteration of the impingement locations of the radiation on the wafer W can also be achieved via a suitable movement of the wafer W relative to the infrared illumination element.
(25) Various embodiments for altering the structure position (i.e. for eliminating possible overlay errors) are described below with reference to
(26) In accordance with
(27) An alteration of the size of the structure that possibly takes place in addition owing to the etching process can be corrected with the aid of one of the methods described above with reference to
(28) In a further embodiment, for altering the structure position, it is also possible to carry out heating of the photoresist in conjunction with a displacement of the structures produced therein by the generation of defined forces: while flowing of the photoresist is brought about by heating of the photoresist beyond the flow temperature thereof (which may be e.g. of the order of magnitude of 120 C.), an asymmetry of this flowing can be achieved by way of a force acting parallel to the wafer surface. This last can be achieved e.g. via a repeated off-axis rotation of the wafer (with in each case a different orientation of the wafer relative to the connecting axis wafer rotation axis), as is illustrated merely schematically in
(29) In further embodiments, a displacement of the structure positions produced on the wafer can also be carried out via a spatially resolved subsequent IR illumination using a device analogous to the embodiment from
(30) In accordance with a further embodiment illustrated merely schematically in
(31) Even though a description has been given above of diverse embodiments for realizing the aftertreatment according to the disclosure of the wafer for the purpose of correcting deviations of structure properties (i.e. structure size and/or structure position) on the exposed wafer, in the context of the present disclosure it is desirable temporally firstly to carry out the ascertainment of the relevant deviations.
(32) In this respect, various embodiments are described below with reference to
(33) As far as firstly ascertaining deviations with regard to the structure size is concerned, this can be carried out according to the disclosure on the basis of the concentration of free hydrogen ions produced in the photoresist or on the wafer. Since correction methods for the structure size alter the number of free hydrogen ions, in particular, the desired correction can be determined directly by ascertaining the actual number of hydrogen ions present, without a structure size on the wafer having to be explicitly determined for this purpose.
(34) The concentration of free hydrogen ions can be determined e.g. on the basis of a measurement of the change in impedance of the photoresist. This can exploit the fact that the free hydrogen ions and/or acids produced during the exposure alter the impedance of the photoresist, wherein the local acid density can in turn be derived from a measurement of this change in impedance. In this respect, reference is made to the publications C. M Berger, J. D. Byers, and C. L. Henderson, J. Electrochem. Soc., 151, G119 2004; C. M Berger and C. L. Henderson, J. Vac. Sci. Technol. B, 22, 1163 2004 and C. Berger and C. L. Henderson, Proc. SPIE, 5753, 1076 2005.
(35) In a further embodiment, the relevant resist parameters (i.e. in particular the local acid density and/or the concentration of free hydrogen atoms) can also be ascertained with the aid of infrared spectroscopy. A so-called Fourier transformation infrared spectrometer (FTIR spectrometer) is suitable here, in particular, since a measurement of the time dependence of the field strength that is carried out in this case is able to be implemented metrologically more simply than ascertaining this variable as a function of the wavelength.
(36) In further embodiments, instead of the measurement of the concentration of free hydrogen ions that is present in the photoresist, it is also possible to ascertain the cause of the establishment of this concentration, i.e. the intensity distribution or pupil filling respectively produced within the illumination unit or the projection lens.
(37) For this purpose, in accordance with
(38) The functionality (already known per se for the dose control of the light source) of the perforated mirror 81 can then be extended according to the disclosure in the sense of a spatially resolved measurement of the intensity in order to be able to calculate the location dependence of the illumination at the reticle. Here the sensor 82 should be configured such that it can also determine a location-dependent dose in addition to a total illumination dose, that is to say the dose integrated over the entire sensor. While the total illumination dose has to be determinable comparatively rapidly since the total illumination dose is used for readjusting the light source power, the spatially resolved measurementsince it does not serve for readjusting the light source powercan be carried out comparatively slowly (e.g. on a time scale of 1 s or more).
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(40) In further embodiments, the desired information about the location dependence of the reticle illumination can also be determined in a projection exposure apparatus designed for operation in the EUV, in respect of which embodiments are described below with reference to
(41) In principle, from time to time a measurement of the intensity profile generated in the illumination unit can be carried out for this purpose. In accordance with
(42) In accordance with
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(45) In principle, for this purpose, in a system designed for operation in the DUV range (e.g. at wavelengths of approximately 193 nm), it is possible once again to use a perforated mirror analogously to
(46) Furthermore, in a set-up for spatially resolved telecentricity measurement as illustrated schematically in
(47) In accordance with a further embodiment illustrated schematically in
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(51) In accordance with
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(53) The illumination unit 201 includes a light source 202 and an illumination optical unit symbolized in a greatly simplified manner by lens elements 203, 204 and a stop 205. In the example shown, the operating wavelength of the projection exposure apparatus 200 is 193 nm with the use of an ArF excimer laser as light source 202. However, the operating wavelength can for example also be 248 nm with the use of a KrF excimer laser or 157 nm with the use of an F2 laser as light source 202. Between the illumination unit 201 and the projection lens 208, a mask 207 is arranged in the object plane OP of the projection lens 208, the mask being held in the beam path via a mask holder 206. The mask 207 has a structure in the micrometers to nanometers range, which is imaged onto an image plane IP of the projection lens 208 with its size reduced by a factor of 4 or 5, for example, via the projection lens 208. The projection lens 208 includes a lens element arrangement, which is likewise symbolized merely in a greatly simplified manner by lens elements 209 to 212 and by which an optical axis OA is defined. A substrate 216 positioned by a substrate holder 218 and provided with a light-sensitive layer 215, or a wafer, is held in the image plane IP of the projection lens 208. An immersion medium 250, which can be deionized water, for example, is situated between the last optical element 220 of the projection lens 208 on the image plane side and the light-sensitive layer 215.
(54) Even though the disclosure has been described on the basis of specific embodiments, numerous variations and alternative embodiments are apparent to the person skilled in the art, e.g. through combination and/or exchange of features of individual embodiments. Accordingly, for the person skilled in the art it goes without saying that such variations and alternative embodiments are concomitantly encompassed by the present disclosure, and the scope of the disclosure is restricted only within the meaning of the accompanying patent claims and the equivalents thereof.