In this contribution the design, realization, and characterization of a transmission grating spectrograph (TGS) designed for spectral characterization and monitoring tasks at extreme-ultraviolet (EUV) wavelengths are presented. The overall dimensions of the EUV-TGS have been minimized to allow for easy integration in existing beamlines and setups while maintaining sub-Ångström spectral resolution. The main module (length = 40 mm) of the realized EUV-TGS consists of a spectral and a spatial filter and a high-resolution phase-shifting transmission grating with a grating structure periodicity of 80 nm. For spectral characterization and monitoring of a plasma-based EUV radiation source, a two-dimensional detector is positioned in close proximity to the main module. The realized spectrograph prototype can be moved in and out of the beam path, and therefore does not affect spot profiling and general beam alignment tasks. The structural and optical design and performance measurements of the EUV-TGS are presented, demonstrating that this ultra-compact spectrograph can be easily integrated into EUV setups that will benefit from an inline diagnostic option.
This paper focuses on the design and fabrication of phase-shifting transmission masks tailored for high-resolution nanopatterning using a compact EUV exposure tool. The authors analyze various factors that influence the achievable resolution, aiming to push the boundaries towards the sub-10 nm range, approaching the theoretical resolution limit. The demand for high-resolution nanoscale patterns spans across diverse applications, driving the need for compact exposure tools and lithographic concepts. The developed EUV exposure tool can be operated at either 10.9 nm or 13.5 nm exposure wavelengths depending on the specific use case. This capability allows for large area nanopatterning with enhanced throughput as well as industrial resist qualification with focus on highest resolution. The utilized discharge-produced plasma (DPP) EUV source offers partially coherent radiation. For this radiation type, the (achromatic) Talbot lithography has proven to be the most effective with resolution in the sub-30 nm range and a theoretical resolution limit of less than 10 nm. To optimize the intensity distribution in the wafer plane, the authors use rigorous coupled-wave analysis (RCWA) simulations to fine-tune the material composition and geometry of the masks. Various factors influencing the achievable resolution are identified and presented. In addition to simulative optimization, the fabrication of dense periodic nanopatterns poses increasing challenges for smaller periods. In this work, the mask fabrication process is optimized to produce stable and high-resolution periodic mask patterns, leading to record resolutions for both line and contact hole periodic nanopatterns with the presented setup.
In this contribution, the authors present the design and fabrication of optimized phase-shifting transmission masks for high-resolution nanopatterning with a compact EUV exposure tool. Several influencing factors on the achievable resolution are determined and characterized, paving the way towards the theoretical resolution limit in the sub-10 nm range. Applications that require high resolution patterns are numerous, leading to an increasing demand for compact exposure tools and lithographic concepts. The realized exposure tool is a compact and versatile setup, that can be operated either at an exposure wavelength of 10.9 nm or 13.5 nm addressing both large area nanopatterning with maximized throughput and industrial resist qualification with highest resolution. For partially coherent radiation as provided by the utilized discharge-plasma produced (DPP) EUV radiation source of the setup, the (achromatic) Talbot lithography has proven to be the most suitable lithographic approach with a demonstrated resolution in the sub-30 nm regime and a theoretical resolution limit below 10 nm. To maximize the contrast of the resulting intensity distribution in wafer plane, the material composition and geometry of the mask are optimized by means of rigorous coupled-wave (RCWA) simulations. Different influencing factors on the achievable resolution are identified and presented. In addition to the simulative optimization of the phase-shifting masks, the fabrication of the dense periodic nanopatterns becomes more and more challenging for smaller periods. In this contribution the mask fabrication process is optimized to create stable and high-resolution periodic mask patterns, leading to record resolution for both line and pinhole periodic nanopatterns with the presented setup.
Background: In the extreme ultaviolet (EUV) lithography process the performance of the photoresist is a crucial factor regarding the quality and critical dimensions of the fabricated structures.
Aim: The characterization of the latent image structures in photoresists during the process steps before the development of the resist is key to understand the relation between the material of the resists, the selection of process parameters, and the resulting quality of fabricated structures.
Approach: Spectroscopic EUV reflectometry is a nondestructive metrology technique that measures the broadband reflectance of samples in the EUV spectral range and under grazing incidence angles. The technique offers a combination of high sensitivity to nanoscale structural parameters of periodic structures as well as a high sensitivity to the material composition samples, enabling the characterization of latent images of periodic structures.
Results: Measurements of the reflectance of an EUV-exposed and unexposed photoresist reveal the contrast in optical constants after the resists are treated with a post-exposure bake as well as shrinkage of the resist layer thickness. Based on this data, simulative studies on latent images of periodic grating structures are conducted showing the possibility to extract information on the structure parameters including the latent image profile and surface topography.
Conclusion: Spectroscopic EUV reflectometry shows to be sensitive to the contrast of exposed and unexposed photoresist which commends the technique to be adequate for the characterization of latent images in photoresists.
Applications that require high resolution patterns are numerous, leading to an increasing demand for compact patterning tools and alternative lithographic concepts. For many scientific applications like biosensing or fabrication of metamaterials, or artificial crystals, the achievable resolution and the patterned area of the fabrication process are of main importance. In the field of high-volume manufacturing, there is a need for high-resolution patterning at the industrial exposure wavelength of 13.5 nm. The main industrial application for compact exposure tools is EUV photoresist development and its related process optimization. The overall patterned area is of minor interest. Instead, the focus is placed on the achievable resolution and quality of the intensity distribution used for the patterning tests. The realized EUV dual beamline allows to address both application fields in a single in-lab setup. By operating the source with an argon/xenon (Ar/Xe) gas mixture, a narrowband spectrum with a main wavelength of 10.9 nm is created without the need of spectral filtering. The resulting intensity of up to 2 mW/cm2 in wafer plane allows large area patterning with highest throughput of several mm2/min. Single exposure fields of 2 x 2 mm2 can be stitched together to achieve an overall patterned area of up to several cm² with minimal stitching borders of ~ 1 μm. By inserting a customized multilayer mirror into the beamline, the emission spectrum of the DPP source (operated with pure Xe gas) is in-band filtered to 13.5 nm, thus allowing qualification of industrial photoresists regarding sensitivity, contrast and resolution. The mask-wafer positioning system for the 13.5 nm beamline is designed for maximum rigidity to minimize relative movements between the mask and wafer that would lower the achievable resolution. Multi-field resolution test masks are created in-house and are exposed in a parallel manner to determine the achievable resist resolution in an efficient manner. Transmission mask designs are optimized by a rigorous simulation model. By tuning the pattern geometry on mask, different patterns like contact holes or nanopillars can be created on the wafer, tailored to the required application.
Background: EUV lithography has been introduced for semiconductor fabrication, which makes maximizing yield and throughput increasingly important. One key component is the use of a high-transmission pellicle to keep particles out of the focal plane and thereby minimize their impact on imaging. Imec initiated the development of a promising pellicle approach based on a network of carbon nanotubes (CNT), which has the advantage of many tunable structural parameters to form a pellicle membrane. A balance between membrane robustness and particle nonpermeability on one side and low EUV absorption and membrane scattering on the other must be found. The membrane scatter is important for EUV flare effects during wafer printing.
Aim: The experimental measurement of the flare must be determined as a function of the tunable CNT structural parameters. However, this measurement can be very challenging for the low-flare requirements involved.
Approach: The EUV scatter measurements on CNT-based pellicle membranes have been performed and optimized in a stand-alone irradiation setup at RWTH Aachen University. The measurement results were compared to flare simulations using a CNT cylinder model, which is used to improve the experimental measurements.
Results: With this approach, the flare of pellicles with different CNT structures and network parameters are investigated, as well as CNT pellicles that incorporate protective coatings.
Conclusion: The proposed flare measurement procedure can be used to test for acceptable scattering levels for EUV imaging applications.
EUV lithography is introduced in semiconductor fabrication processes, which makes maximizing yield and throughput increasingly important. One key component is the use of a high-transmission pellicle to keep particles out of the focal plane and thereby minimize their impact on imaging. Imec initiated the development of a promising pellicle approach based on a network of carbon nanotubes (CNT), which has the advantage of many tunable structural parameters to form a pellicle membrane. A balance between membrane robustness and particle non-permeability on one side and low EUV absorption and membrane scattering on the other, must be found. The membrane scatter is important for EUV flare effects during wafer printing. Therefore, it is important to verify its magnitude experimentally as a function of the tunable CNT structural parameters. However, this measurement can be very challenging for low-flare requirements. In this work, the EUV scatter measurements on CNT-based pellicle membranes have been performed and optimized in a stand-alone irradiation setup at RWTH Aachen University. Membranes with different CNT structures and network parameters are investigated, as well as membranes with protective coatings. These measurements, in combination with scattering calculations and printing performance, can serve as a guideline on acceptable scattering levels for industrial applications.
The authors present latent image characterization in photoresists by means of extreme ultraviolet (EUV) spectroscopic reflectometry. The optical constants of photoresists before and after exposure are measured in the EUV spectral range. Latent images are investigated in the form of periodic line gratings. The investigation is performed by the analysis of spectroscopic reflectance curves in the wavelength range from 5 nm to 20 nm at grazing incidence angles. Through an analysis of the reflectance curves based on rigorous electromagnetic modeling, a characterization of parameters of interest of the latent image is evaluated. This includes the latent image profile, surface topography and stochastic-related parameters such as line edge roughness.
The EUV laboratory exposure tool (EUV-LET) is a compact nanostructuring setup used for large-area patterning of arbitrary to periodic structures as well as industrial photoresist characterization in terms of sensitivity, contrast and resolution. The setup utilizes partially coherent radiation of a compact discharge-produced plasma (DPP) EUV source, spectrally filtered by a multilayer mirror to a wavelength of 13.5 nm with 4 % bandwidth (full width at half maximum, FWHM). The system is equipped with a precise positioning system for mask and wafer, which allows resist exposures at defined distances. For the generation of large area nanopatterns, the achromatic Talbot lithography is applied which is well suited for high-resolution patterning of periodic structures with partially coherent radiation from plasma-based EUV sources. Optimized transmission masks enable the generation of contrast rich intensity modulations leading to structure sizes below 40 nm. The theoretical resolution limit is in the sub-10 nm range by taking advantage of a two times mask pattern demagnification. The achievable practical resolution is mainly limited by the fabrication of the required transmission masks and the optical properties of the mask illumination. In this contribution, the EUV-LET serves as a basis to identify design rules for core building blocks of a future industrial EUV resist qualification setup (EUV-REQS). These core building blocks try to overcome the main limitations to resist testing at highest resolution as stated above. For the optimization of the illumination properties, the design of highly efficient illumination optics is investigated and presented. Aims of the illumination optics are the generation of high throughput, homogeneous illumination of the patterned mask area and the optimization of the EUV radiation properties to fulfill the requirements for Talbot lithography. For the generation of high-resolution intensity patterns in wafer plane, the design of resolution test masks is analyzed and evaluated by means of the achievable resolution and patterning uniformity. The fabrication of a resolution test mask and selected exposure results are shown as well.
When it comes to the patterning of periodic structures like lines and spaces or contact hole arrays interference lithography can be effectively applied. By the use of ultrashort wavelengths in extreme ultraviolet (EUV) range, structure sizes can be pushed into the sub-100 nm region. Using advanced interference schemes, such as achromatic Talbot imaging, high-quality large-area patterning can be realized, e.g. for resist stochastics tests as well as for advanced fabrication processes in research and also small-batch production. Since the Talbot lithography only requires medium spatial coherence and accepts broadband emission, the approach can be used not only with coherent radiation as provided by synchrotron facilities but also with compact plasma-based EUV sources. In this contribution the theoretical resolution limit for the achromatic Talbot lithography is determined by simulations for the use of optimized phase-shifting transmission mask concepts illuminated by compact discharge-produced plasma EUV source operating at a main wavelength of 13.5 nm. The further effects that reduce a practical resolution limit, such as mask imperfections, positioner instabilities and resist contrast are also considered. With the realized EUV laboratory exposure tool and polymer-based contact hole phase-shifting masks 28 nm resolution has been demonstrated so far. Main limitations are found in the mask fabrication process that cannot be further down-scaled due to increasing aspect ratios and pattern degradation of the mask structures. To extend the developed nanopatterning technology to the sub-30 nm region, optimized phase-shifting transmission masks have to be designed and fabricated, enabling a contrast-rich intensity modulation in wafer plane. As size of the mask openings is approaching the exposure wavelength, mask geometry has to be optimized for every node. In this paper rigorous simulations of new mask designs optimized for the achromatic Talbot lithography are presented. For selected phase-shifting transmission masks, the influence of the mask material and geometry on the resulting aerial image is evaluated along with an analysis of the theoretical resolution limit.
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