This invention relates generally to semiconductor devices, and more specifically, to methods of manufacturing semiconductors with photoresist masks.
As manufacturing of semiconductors has involved smaller and smaller dimensions, the photolithography has been moving to smaller and smaller wavelengths. The light provided at these reduced wavelengths has resulted in the need for different photoresists. This has been caused not just by the change in character of the light due to wavelength but also the reduced intensity of the light. With these required changes in the photoresist, the photoresists have also changed in their composition and thus affect semiconductor processing chemistries.
As the semiconductor dimensions shrink, the conventional thickness of photoresist masks also needs to shrink. For example, when the dimension between adjoining semiconductor well regions that are separated by a narrow isolation shrinks, a conventional photoresist mask has a high aspect ratio which is difficult to pattern. Therefore, a thinner photoresist typically allows more depth of focus and process latitude. Also, the height of the photoresist causes unwanted shadowing of angled implants used at various points in semiconductor processing.
Photoresist layers are often used as a masking layer to direct implantation in only certain areas. A known method to avoid the issues caused by thick photoresist is to use a thinner resist. However, thinner photoresists have the inherent disadvantage of a reduced stopping ability for any implantation process. When thin photoresists are used in conventional processes, a breakthrough may occur during an implant step and negatively impact the semiconductor devices in regions under the photoresist.
In U.S. Pat. No. 6,815,359 Gabriel et al. propose a plasma process for treating a photoresist with fluorine wherein only exposed outer surfaces of the photoresist are modified. A plasma process is typically at an elevated process temperature, and the processing equipment and chemistry are complex. Plasma processes act by enhancing cross-linking of a polymer contained in the photoresist. This cross-linking is known to lead to stresses in the photoresist which can lead to modification or deformation of the intended pattern. A disadvantage of having a treated photoresist layer only at exposed surfaces is that various subsequent processing, such as etching and implanting, can readily penetrate the thin treated portion of the photoresist. Once penetrated, the remaining area of the photoresist is vulnerable and may fail to provide the desired masking protection.
U.S. Pat. No. 6,544,894 is another example of a photoresist mask that is plasma treated with a fluorine-containing gas to enhance etching resistance. The process taught therein addresses the manufacturing of chromium masks which will subsequently be used in semiconductor processing. These masks are formed by patterning photoresist layers and etching the chromium. By introducing fluorine into the photoresist, the photoresist becomes less susceptible to degradation during the chromium etch step. The manner of introducing fluorine is similar to that described in U.S. Pat. No. 6,815,359 described above and thus suffers the same disadvantages.
The present invention is illustrated by way of example and not limited to the accompanying figures, in which like references indicate similar elements.
Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present invention.
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The ability of the light 28 to uniformly react in the desired region 25 depends upon the wavelength of the light and the height of the photoresist layer 24. Conventional photoresist layers are relatively thick in comparison with the distance between two isolated semiconductor features. The height of the photoresist layer may lead to inaccuracies in the patterning. In particular, due to the relative depth of the opening, the light will scatter in a manner that leads to less light reaching the surface to be exposed. Since the wavelength is fixed for a given semiconductor generation, the height of the photoresist layer 24 is the primary variable that can be adjusted. However, photoresist layer 24 may not be readily thinned to address this problem because at lower thicknesses the photoresist does not adequately function as a mask for subsequent implant steps.
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At this point it should be appreciated that there has been provided a method for enhancing a photoresist layer with a molecular halogen for the purpose of enabling a thinner photoresist layer to be used without negative consequences. Although a discussion of molecular fluorine has been made, other elements which are halogens may be used. The penetration of molecular fluorine into the photoresist is dependent upon time, temperature and pressure. With a constant temperature and pressure, increased time exposure to the molecular fluorine gas allows deeper penetration into the photoresist. It is possible that molecular fluorine will penetrate to the lower portion of the photoresist. The fluorine profile in the photoresist may be either non-uniform or uniform in nature. To obtain a uniform fluorine profile, additional processing of the photoresist layer is needed. This additional processing includes either additional time, increased pressure, increased temperature or all of the above. It should be understood that rather than using molecular fluorine in a gas phase, a liquid fluorinating agent may be used instead to obtain a uniform fluorine profile. By using the disclosed method a very thin photoresist layer may be implemented. Exemplary thicknesses of photoresist that are fluorinated using the disclosed methods are one-half micron and less.
In the foregoing specification, the invention has been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. For example, while the semiconductor devices described herein are in the context of metal oxide semiconductor (MOS) technology, it should be understood that various semiconductor processes may be used. Such processes include, but are not limited to, gallium arsenide and bipolar semiconductor processes. Various other structures may be used. For example, silicon on insulator (SOI) may be used and various transistor structures may be implemented. Such other transistor structures include elevated source/drain devices. Similarly, the semiconductor circuit function may vary widely from memory and data storage circuitry, digital signal processing (DSP), processor and microcontroller circuitry as well as special function logic circuitry.
The treating of a photoresist film by using a molecular halogen or a liquid fluorinating agent is chemically different than previous suggested treatments of fluorine in a plasma. In addition to increased complexity and expense associated with a plasma, the exposure of photoresist to fluorine in a plasma is chemically limiting so that only exposed surfaces of the photoresist become fluorinated. When a plasma is used the reaction that produces fluorination results from chemical linking of elements. This reaction by its nature does not penetrate further than a small perimeter region. Therefore, the use of a plasma does not allow photoresist to be made smaller without the consequences associated with subsequent implanting of having shadowing as described herein and inadequate blocking of implanted ions. In contrast, the use of a molecular halogen or a liquid fluorinating agent functions chemically to replace hydrogen contained within the photoresist and penetrate an entire depth of a photoresist layer. While any depth percentage of fluorination of the photoresist may be implemented using the methods described herein, when very thin photoresist layers are used in state-of-the-art processes having extremely small dimensions it is more likely that all of the photoresist layer needs to be fluorinated for enhanced ion implant blocking.
In one form there is herein provided a method of making a device structure by providing a semiconductor substrate. A layer of photoresist is deposited over the substrate. The layer of photoresist is patterned to form a layer of patterned photoresist. A molecular halogen or a liquid fluorinating agent is flowed over the layer of patterned photoresist to form a layer of treated photoresist. An implant is performed using the layer of treated photoresist as a mask to the implant to form an implanted region in the substrate. Formation of the device structure is completed, wherein the device structure includes the implanted region. In one form the molecular halogen is molecular fluorine (F2). In other forms the molecular halogen is one of bromine (Br2), chlorine (Cl2) or iodine (I2). In another form molecular halogen is flowed by flowing nitrogen, wherein the molecular halogen has an atomic concentration of about 1 percent. In yet another form the molecular halogen is flowed at a temperature below 50 degrees Celsius and above 10 degrees Celsius. In another form the layer of photoresist comprises hydrogen and the flowing the molecular halogen or the liquid fluorinating agent results in replacing hydrogen atoms with halogen atoms. In another form the layer of patterned photoresist has a first thickness and flowing the molecular halogen or the liquid fluorinating agent results in replacing hydrogen atoms with halogen atoms to at least half of the first thickness. In another form hydrogen atoms are replaced with halogen atoms at substantially all depth levels of the patterned photoresist. In one form the implant is a halo implant. In another form the implant is a well implant. Each of the molecular halogen and the liquid fluorinating agent comprises fluorine. The layer of treated photoresist has a top surface. The layer of patterned photoresist comprises hydrogen. The step of flowing replaces hydrogen atoms with fluorine atoms and is for controlling a profile of the fluorine atoms from the top surface to control a profile of molecular weight of the patterned photoresist. In yet another form the molecular halogen is flowed at a pressure of at least 120 Torr.
In another form there is provided a method of making a device structure by providing a semiconductor substrate and depositing a layer of photoresist over the substrate. The layer of photoresist comprises hydrogen and is patterned to form a layer of patterned photoresist having an exposed top surface, a bottom surface that is closest to the substrate, and a first thickness from the exposed top surface to the bottom surface. A molecular halogen or a liquid fluorinating agent is flowed over the layer of patterned photoresist to form a layer of treated photoresist by replacing substantially all of the hydrogen from at least the exposed top surface to half of the first thickness. An implant is performed using the layer of treated photoresist as a mask to the implant to form an implanted region in the substrate. In one form the molecular halogen comprises molecular fluorine (F2). In another form the molecular halogen comprises one of the group consisting of chlorine, fluorine, bromine, and iodine. In yet another form the molecular halogen comprises about 1 percent fluorine: The molecular halogen is carried by nitrogen at a flow rate of about 1000 standard cubic centimeters per minute (SCCM). The flowing the molecular halogen is performed at a temperature between 10 and 50 degrees Celsius. In another form the implant comprises one of a group consisting of a well implant and a halo implant.
In yet another form there is provided a method of making a device structure by providing a semiconductor substrate having a first region for forming N channel transistors and a second region for forming P channel transistors. A first layer of photoresist is deposited over the substrate wherein the layer of photoresist comprises hydrogen. The first layer of photoresist is patterned to form a first layer of patterned photoresist over the first region, wherein the first layer of patterned photoresist has an exposed top surface, a bottom surface that is closest to the substrate, and a first thickness from the exposed top surface to the bottom surface. A first molecular halogen is flowed over the first layer of patterned photoresist to replace substantially all of the hydrogen from the first layer of patterned photoresist from at least the exposed top surface to half of the first thickness. A well implant is performed using the first layer of treated photoresist as a mask to the implant to form the N-well. The first layer of treated photoresist is removed. A gate is formed over the N-well. A second layer of photoresist is deposited over the first region. The second layer of photoresist is patterned to form a second layer of patterned photoresist over the first region and exposing the second region. A second molecular halogen is flowed over the second layer of patterned photoresist. An angled implant is performed to form a halo region under the gate. Source/drain regions are formed in the second region substantially adjacent to the gate, wherein the device structure is a transistor. In another form the first molecular halogen and second molecular halogen comprise molecular fluorine (F2). In yet another form the first molecular halogen and the second molecular halogen each comprise a same or a differing one of a group consisting of chlorine (Cl2), fluorine (F2), bromine (Br2), and iodine (I2).
Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims. As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. The terms a or an, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term coupled, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
This application is a continuation-in-part under 37 C.F.R. 1.53(b) of the following pending application: (1) U.S. Ser. No. 10/779,007 entitled “Method of Masking A Semiconductor Device Using Treated Photoresist” filed on Feb. 13, 2004 by Garza et al. and assigned to the assignee hereof.
Number | Date | Country | |
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Parent | 10779007 | Feb 2004 | US |
Child | 11143295 | Jun 2005 | US |