Revolutionary and evolutionary resist design concepts for 193 nm lithography

The intense absorption of aromatic molecules at 193 nm severely limits the use of conventional matrix aromatic resins such as novolac, poly vinyl phenol for 193 nm lithography. This paradigm shift in resist design provides opportunities for new chemistries and process schemes to provide the required aqueous base solubility, etch resistance, resolution, photospeed and process latitude. In addition, regulatory constraints on the volatile organic emissions (VOC) also provide opportunities to design revolutionary resist schemes that not only address the lithographic performance requirements but also alleviate the environmental safety and health (ES&H) aspects of resist technology. In this paper, we will analyze the several resist options available for 193 nm lithography and provide results for evolutionary single layer, bilayer and revolutionary “all-dry” plasma polymerized methyl silane (PPMS) resist schemes. For single layer schemes, we have synthesized several co- and terpolymers with cycloolefins, maleic anhydride and acrylates (acrylic, methacrylic acids and esters) and have used the protected polymers as matrix resins in three component systems with a photoacid generator (PAG) and dissolution inhibitor(s) (DI). Alternately, we have used the unprotected terpolymer with DI's and PAG in three component systems. The lithographic results for single layer and bilayer resist materials were obtained at 193 nm using a 0.55 NA Nikon or 0.56 NA ISI (Integrated Solutions Inc.) small field exposure systems. Single layer resist materials showed at least 0.16 μm l/s pair resolution and modulation down to 0.14 μm l/s pairs using a formulation and process optimized at 248 nm. We have also evaluated the performance of P(SI-CMS) (poly(trimethyl silyl methyl methacrylate-co-chloromethyl styrene), a negative e-beam resist, at 193 nm and have obtained 0.25 μm l/s pair resolution without much optimization. Structure-activity relationships between the polymer properties and lithographic performance for this system have been identified. The results obtained for PPMS, a plasma deposited all-dry resist technology, on the 193 nm Micrascan (0.50 NA) were also very encouraging. Again using a non-optimized process, we have obtained at least 0.15 μm l/s pair resolution in a bilayer scheme.