Open Access Article
Zhihao
Wang
a,
Jinping
Chen
*a,
Tianjun
Yu
a,
Yi
Zeng
a,
Xudong
Guo
b,
Shuangqing
Wang
b,
Rui
Hu
b,
Peng
Tian
c,
Michaela
Vockenhuber
c,
Dimitrios
Kazazis
c,
Yasin
Ekinci
*c,
Guoqiang
Yang
*b and
Yi
Li
*a
aKey Laboratory of Photochemical Conversion and Optoelectronic Materials, Technical Institute of Physics and Chemistry, University of Chinese Academy of Sciences, Chinese Academy of Sciences, Beijing 100190, China. E-mail: chenjp@mail.ipc.ac.cn; yili@mail.ipc.ac.cn
bKey Laboratory of Photochemistry, Institute of Chemistry, University of Chinese Academy of Sciences, Chinese Academy of Sciences, Beijing 100190, China. E-mail: gqyang@iccas.ac.cn
cPaul Scherrer Institute, Laboratory for X-ray Nanoscience and Technologies, CH-5232 Villigen, Switzerland. E-mail: yasin.ekinci@psi.ch
First published on 13th February 2024
A single-component nonchemically-amplified resist (n-CAR) based on a tetraphenyltin derivative (SnMSF4) was developed for electron beam and extreme ultraviolet lithography. The structure of SnMSF4 was characterized by 1H NMR, 19F NMR, HRMS, FTIR spectroscopy, and elemental analysis. SnMSF4 exhibits good thermal stability, and its non-planar structure makes it have good film-forming performance, which makes it suitable for resist materials. SnMSF4 can be used as a negative resist developed with water (H2O), mixtures of ethanol (EtOH) and H2O (VEtOH
:
VH2O = 1
:
10–20), or mixtures of isopropyl alcohol (IPA) and H2O (VIPA
:
VH2O = 1
:
10–20). Electron beam lithography (EBL) studies revealed that 20 nm features were successfully patterned using the SnMSF4 resist. Moreover, the study of extreme ultraviolet lithography (EUVL) performance shows that 13 nm line/space (L/S) patterns were successfully patterned at a dose of 163 mJ cm−2 with a line edge roughness (LER) of 3.3 nm. Further studies on the underlying mechanisms showed that the solubility change of the SnMSF4 resist depends on the decomposition of the sulfonium group. This research will provide useful guidance for the research of high-resolution electron beam and EUV resist materials.
Chemically-amplified resists (CARs) have been widely used in the semiconductor industry for several decades due to their excellent sensitivity. However, the inherent acid diffusion blur in CAR films results in poor line edge roughness (LER), especially for patterns with a half-pitch (HP) below 20 nm. Compared with CARs, nonchemically-amplified resists (n-CARs) exhibit the potential to form high-resolution patterns due to the advantages of single-component characteristics and the lack of acid diffusion and issues due to delay after baking.4,10,11 Various types of n-CARs containing radiation-sensitive groups, e.g. sulfone,12 carbonate,13,14 oxalate,15 organic ligands of organometallic compounds,16–19 and sulfonium groups,10,20–23 have been reported. Whittaker et al. reported a series of chain-scission resist polymers with a highly degradable poly(1-pentene sulfone) backbone and PMMA arms. EUVL studies showed that the resist was capable of resolving 30 nm line/space (L/S) patterns.12 Blakey et al. designed a series of polycarbonate polymers and realized patterning with a feature size of 28.6 nm after development optimization.14 Inorganic oxalate compounds were developed by Brainard et al. for EUVL, and achieved 20 nm L/S patterns at doses approaching 30 mJ cm−2.15 In addition, metal organic compound resists, such as metal xanthates,6 tin-oxo clusters16 and heterometallic rings,19 can also be used for EBL or EUVL, and exhibit high resolution but low sensitivity. In recent years, resist materials containing sulfonium groups have been widely studied due to their higher resolution and moderate sensitivity. Gonsalves' group developed a series of negative-tone n-CARs bearing radiation-sensitive sulfonium groups,4,22–25 successfully demonstrating 15 nm features using MAPDST-TIPMA resists and EBL.4 In addition, well-resolved sub-15 nm nanofeatures with a low LER of ∼1.29 nm were achieved by using the MAPDST-co-ADSM resist. The sensitivity of MAPDST-co-ADSM can be improved by increasing the proportion of tin-containing ADSM monomers.23 Our previous research focused on molecular CARs based on bisphenol A,26 spirobifluorene,5 tetraphenylsilane,27 and adamantane derivatives3 for EBL and EUVL, achieving patterns with a high resolution and low LER. Recently, our research group reported a series of n-CARs bearing sulfonium groups based on polystyrene, in which PSTS0.7 achieved 13 nm L/S patterns through EUVL.10,20 By rational design of nonchemically-amplified molecular resists, which combine the advantages of molecular resists with the concept of non-CARs, we anticipate an enhancement in the sensitivity and resolution of the lithographic patterns.
In this work, a novel molecular n-CAR based on the dimethylsulfonium-functionalized tetraphenyltin (SnMSF4) was designed and synthesized, as shown in Fig. 1. The tin element acts as the electron or EUV absorber due to its high elemental absorption coefficient1,23 and the four dimethylphenyl sulfonium groups act as the photosensitive and solubility conversion groups. The tetrahedral tetraphenyltin as the core and the sulfonium group at the meta position are beneficial to the low crystallinity and good film-forming ability of the molecule. The lithographic performance of the SnMSF4 resist has been extensively evaluated by EBL and EUVL, achieving HPs of 20 and 13 nm line/space patterns developed in water, respectively.
:
VH2O = 1
:
10–20), or the mixtures of IPA and H2O (VIPA
:
VH2O = 1
:
10–20) and blow-dried with N2. The lithographic results are characterized by SEM and AFM. SEM images were captured using a Hitachi S8230 scanning electron microscope. The line width and line edge roughness (LER) were measured and calculated by analyzing the SEM images with ProSEM software. AFM images were captured using a Bruker Multimode 8 (Veco, USA).
Compared with polymer materials, compounds with a small molecular weight are more likely to crystallize, resulting in the inability to prepare resist films by spin coating.29,30 To confirm the film forming properties of SnMSF4, atomic force microscopy (AFM) is used to analyse the surface of the SnMSF4 resist film (thickness: ∼30 nm) prepared by spin coating. As shown in Fig. 3, the resist thickness fluctuates in the range of ±2 nm and the surface roughness (Rq) of the SnMSF4 film was only about 0.2 nm in an area of 5 × 5 μm2. The results show that the surface of the SnMSF4 resist film is smooth without crystallization, which meets the requirements of high-resolution lithography. The SnMSF4 molecule has a non-planar tetrahedral structure, and the sulfonium group at the meta position of the phenyl ring increases the disorder of the molecule due to the presence of configurational isomers.31 The non-planar structure and the conformational isomerism make SnMSF4 unfavorable to crystallization, exhibiting good film-forming ability.
:
VH2O = 1
:
10), and the mixture of isopropyl alcohol (IPA) and H2O (VIPA
:
VH2O = 1
:
10), respectively. Obviously, the SnMSF4 resist exhibits a higher sensitivity when water is used as the developer. This is because when organic solvents such as ethanol or isopropanol are added to the developer, the developer shows better solubility for the resist in the exposed areas. Therefore, a higher exposure dose is needed to decompose more sulfonium groups and ensure that the resist in the exposure area is not soluble in the developer. Similar results were also found in the study of PSTS resists in our previous work.20 The contrast values of the SnMSF4 resist using H2O, the mixture of EtOH and H2O (VEtOH
:
VH2O = 1
:
10), and the mixture of isopropyl alcohol (IPA) and H2O (VIPA
:
VH2O = 1
:
10) for development are 1.15, 1.06 and 1.28, respectively. The result showed that the change of developers has no significant effect on the contrast. The details of the calculation process of the sensitivity and contrast are shown in the ESI.†
The EBL performance of the SnMSF4 resist was further investigated to confirm the effect of developers on resist patterns. Fig. 5 shows the 22 nm L/S patterns of the SnMSF4 resist developed in the different developers for EBL. Consistent with the sensitivity data, the exposure dose required for water development is significantly smaller than that for the mixed developers. The 22 nm L/S patterns without any bridging or collapse are obtained at the dose range of 2000–3000 μC cm−2. When developing with the mixtures of EtOH/IPA and water, the required exposure dose is at least 3200 μC cm−2 to obtain 22 nm L/S patterns. The higher the proportion of EtOH/IPA in the developer, the higher the exposure dose required (Fig. 5). According to the SEM images in Fig. 5, although the sensitivity of the SnMSF4 resist is different, 22 nm L/S patterns can be obtained without significant difference. The influence of developers on resolution will be further studied by exposing the resist to EUV light.
After optimizing the development conditions, water, the mixtures of EtOH and H2O (VEtOH
:
VH2O = 1
:
10–20) and the mixtures of IPA and H2O (VIPA
:
VH2O = 1
:
10–20) can be used as the developers for the SnMSF4 resist. Fig. 6 shows the 40, 30, 25, 22, and 20 nm L/S patterns of the SnMSF4 resist for EBL. The lithographic patterns exhibit a high contrast without any bridging or collapse. These lithographic results prove that SnMSF4 is a high resolution resist material, which can accurately realize the patterning of 20–40 nm L/S patterns by EBL.
:
VH2O = 1
:
10–20) and the mixtures of IPA and H2O (VIPA
:
VH2O = 1
:
10–20) are similar, water and the mixture of IPA and H2O (VIPA
:
VH2O = 1
:
10), the two representative developers, were selected for the EUV lithography studies.
The 16, 15, 14 and 13 nm L/S line patterns of the SnMSF4 resist under different exposure doses developed with water and the mixture of IPA and H2O (VIPA
:
VH2O = 1
:
10) are shown in Fig. S6 and S7.† According to these EUV lithographic patterns with different exposure doses, the optimal exposure doses of the SnMSF4 resist for 16, 15, 14 and 13 nm L/S line patterns can be obtained as shown in Fig. 7. By comparing the results of the two developers, water gives better results than the mixture of IPA and H2O (VIPA
:
VH2O = 1
:
10). The exposure dose required for water development is significantly lower than that for the mixture of IPA and H2O (VIPA
:
VH2O = 1
:
10), which is consistent with the results of EBL. In terms of the resolution of the lithographic patterns, 16 and 15 nm L/S patterns can be obtained by using water as the developer, with low LERs (2.3–2.6 nm). 14 nm and 13 nm L/S patterns were also obtained but with a slight increase in the LER (3.2–3.3 nm). In the case of the IPA and H2O mixture (VIPA
:
VH2O = 1
:
10), only 16 and 15 nm L/S patterns can be achieved. Severe bridging was observed for 14 and 13 nm L/S patterns. The resist for 12 nm L/S lithography was also tested, but the patterns showed a poor contrast and needed further optimization (Fig. S8†).
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Fig. 7 The 16, 15, 14 and 13 nm L/S line patterns of the SnMSF4 resists developed with water and the mixture of IPA and H2O (VIPA : VH2O = 1 : 10). | ||
All the LERs were calculated with the ProSEM software (Fig. S9–S14†). It is obvious that using water as the developer gives better results than the water/alcohol mixture developer. Usually, the surface tension coefficient of the mixture is lower than that of water, which helps to reduce the capillary force and alleviate pattern collapse. However, the addition of alcohol to the developer increases the solubility of the SnMSF4 resist after exposure. This requires a higher exposure dose to achieve a switch of solubility, which also explains the higher sensitivity of the SnMSF4 resist developed in water than in the mixture. Furthermore, the enhanced solubility of the mixture developer leads to a loss of resist film thickness, which results in poor LERs and resolutions.3,32 In general, the water developer not only is environmentally friendly, but also exhibits higher sensitivity, better resolution, and lower LER than the mixture developer for the SnMSF4 resist. It should be noted that the PFAS anion (CF3SO3−) in the SnMSF4 resist containing –CF3 is not environmentally friendly.33 The development of non-PFAS anions may be an option in the future.
The performance of the SnMSF4 resist for EBL and EUVL is summarized in Table 1. The SnMSF4 resist exhibits extremely high resolution and can achieve 20 and 13 nm L/S patterns by EBL and EUVL, respectively. The extremely high resolution of the SnMSF4 resist may be due to the small molecular size and non-chemical amplification characteristics. Some early studies have demonstrated that the introduction of Sn with a high EUV absorption coefficient to the resist can help improve its sensitivity.23 However, it should be noted that the sensitivity of the SnMSF4 resist for EUVL is not significantly increased by the introduction of Sn to the molecule compared with our previous studies on other sulfonium-based n-CARs.11,20,34 This is attributed to the following possible reasons: i) unlike the reported tin-oxo cages,35 the cross-section of the Sn atom in the SnMSF4 molecule is estimated to be only ∼10%, by comparing the cross-section of the Sn atom to the whole molecule,36 which limits its contribution to EUV absorption. Thus, the yield of secondary electrons to irradiate the sulfonium is not increased significantly. ii) The strong EUV absorption does not mean that the secondary electron yield is high, and the secondary electron yield is also related to the energy barrier for secondary electron emission.37
| Resist | Lithography method | Developer | Contrasta | Sensitivityb (μC cm−2 or mJ cm−2) | Resolution (nm) |
|---|---|---|---|---|---|
| a Calculated according to the values of D0 and D100 obtained from the NRT curve. The details of the calculation are shown in the ESI.† The contrast of EUV is not tested due to limited lithography time. b The sensitivity of EBL and EUVL is the optimal exposure dose for patterning. | |||||
| SnMSF4 | EBL | H2O | 1.15 | 2000 | 20 |
EtOH : H2O = 1 : 10 |
1.06 | 3800 | 20 | ||
IPA : H2O = 1 : 10 |
1.28 | 4000 | 20 | ||
| EUVL | H2O | — | 173 | 13 | |
IPA : H2O = 1 : 10 |
— | 253 | 15 | ||
O peaks after exposure (Fig. 8b) indicates that the CF3SO3− anion is partially decomposed. The XPS analysis confirms that the decomposition of CF3SO3− and sulfonium groups in the SnMSF4 resist film occurred during e-beam exposure, which is consistent to the previous report on the sulfonium-based n-CARs in EBL and EUVL by Gonsalves et al. as well as by our research group.20,25,38 Our previous study also demonstrated that similar chemical reactions occur in the film of the sulfonium-based compound by e-beam and EUV light, both of which can generate secondary electrons to induce the chemical reactions.34 Based on the XPS data and the previously reported results, we propose a mechanism for the solubility switch of the SnMSF4 resist (Fig. 8c). The SnMSF4 film is soluble in water due to the four sulfonium groups at the periphery. After e-beam irradiation, the cationic sulfonium group is converted into neutral phenyl methyl sulfide, which is insoluble in water. The anionic triflate is decomposed into fragments, which are released from the resist film. Therefore, the initially water-soluble SnMSF4 resist film changes from hydrophilic to hydrophobic, and a solubility switch is thereby induced by using water as the developer to form a negative pattern.
![]() | ||
| Fig. 8 (a) C 1s and (b) S 2p XPS core spectra of the SnMSF4 resist films before and after e-beam exposure. (c) Proposed decomposition process of sulfonium and CF3SO3− units. | ||
The contrast curves and mechanism analysis show that the SnMSF4 molecule needs to lose most of its polar groups to lose its water solubility, which may be the reason for the low sensitivity of the SnMSF4 resist. Free radical species are indeed produced during the decomposition of the sulfonium group, which leads to the potential of cross-linking reactions in the exposed region. However, previous reports have demonstrated that the bond cleavage occurred mainly at S+–CH3 for the phenyldimethyl sulfonium group, resulting in ·CH3 and Ph–S+·–CH3 radicals.39,40 The following cross-linking of ·CH3 to form CH3CH3 or coupling with Ph–S+·–CH3 to release H+ has no obvious effect on the molecular weight in the case of the SnMSF4 molecule. This suggested that the polarity change caused by the decomposition of the onium salts plays a dominant role in the solubility switch, rather than caused by crosslinking reactions.
Footnote |
| † Electronic supplementary information (ESI) available: Characterization and experimental data. See DOI: https://doi.org/10.1039/d3lf00254c |
| This journal is © The Royal Society of Chemistry 2024 |