Claims
- 1. A process for lithographically patterning a material on a substrate comprising the steps of:
(a) depositing a radiation sensitive material on the substrate by chemical vapor deposition; (b) selectively exposing the radiation sensitive material to radiation to form a pattern; and (c) developing the pattern using a supercritical fluid (SCF) as a developer.
- 2. The process of claim 1 that is a direct dielectric patterning process.
- 3. The process of claim 1 wherein the substrate comprises an underlying dielectric layer and a sacrificial resist layer on top of the underlying dielectric layer.
- 4. The process of claim 1 wherein the radiation sensitive material after selective exposure to radiation results in a positive-type resist.
- 5. The process of claim 1 wherein the radiation sensitive material after selective exposure to radiation results in a negative-type resist.
- 6. The process of claim 3 further comprising the step of transferring the pattern from the sacrificial resist layer to the underlying dielectric layer by etching, and stripping away the sacrificial resist layer.
- 7. The process of claim 1 further comprising the step of:
including a photoacid generator in step (a).
- 8. The process of claim 1 wherein the chemical vapor deposition comprises pyrolytic chemical vapor deposition.
- 9. The process of claim 1 wherein the radiation sensitive material has dielectric constant of less than about 3.0.
- 10. The process of claim 1 wherein the dielectric constant of the radiation sensitive material ranges from about 1.9 to about 2.7.
- 11. The process of claim 1 wherein the radiation sensitive material is selected from the group consisting of a fluorocarbon and an organosilicon compound.
- 12. The process of claim 11 wherein the fluorocarbon comprises poly(CF2).
- 13. The process of claim 12 wherein the poly(CF2) is made by polymerization of difluorocarbene (:CF2).
- 14. The process of claim 13 wherein the difluorocarbene is derived from hexafluoropropylene oxide.
- 15. The process of claim 11 wherein the organosilicon compound is selected from the group consisting of organosilanes and organosiloxanes.
- 16. The process of claim 11 wherein the organosilicon compound is derived from at least one member selected from the group consisting of hexamethylcyclotrisiloxane and octamethylcyclotetrasiloxane.
- 17. The process of claim 1 wherein the radiation used to form the pattern is selected from the group consisting of deep ultraviolet radiation (DUV), extreme ultraviolet radiation, ultraviolet radiation (JV), and x-rays and ion beam.
- 18. The process of claim 1 wherein the radiation used to form the pattern is electron beam radiation.
- 19. The process of claim 17 wherein the wavelength of the deep ultraviolet radiation is a member selected from the group consisting of 193 nm and 157 nm.
- 20. The process of claim 1 wherein the supercritical fluid (SCF) is supercritical carbon dioxide.
- 21. The process of claim 1 wherein the supercritical fluid (SCF) is a mixture of carbon dioxide and at least one member selected from the group consisting of propane, butane, 2,3-dimethylbutane, pentane, toluene, n-hexane, cyclohexane, acetonitrile, methanol, and ethanol.
- 22. The process of claim 1 wherein the substrate is a semiconductor substrate.
- 23. The process of claim 1 wherein the substrate is a silicon wafer.
- 24. The process of claim 1 wherein the substrate comprises an epoxy material, a ceramic material, a magnetic disc, or a printed circuit board.
- 25. A process for lithographically patterning a material on a substrate comprising the steps of:
depositing a radiation sensitive material on the substrate by chemical vapor deposition; selectively exposing the radiation sensitive material to radiation to form a pattern; and developing the pattern using a dry plasma etch.
- 26. A microstructure formed by a process comprising the steps of:
depositing a radiation sensitive material on a substrate by chemical vapor deposition; selectively exposing the radiation sensitive material to radiation to form a pattern; and developing the pattern using a supercritical fluid (SCF) as a developer to form the microstructure; wherein the process is direct dielectric patterning process.
- 27. A microstructure comprising:
a substrate; and a patterned dielectric layer, wherein the patterned dielectric layer comprises at least one two-dimensional feature having a dimensional tolerance more precise than 7% of the dimension of the two-dimensional feature.
- 28. The microstructure of claim 27 wherein the patterned dielectric layer is formed by a direct patterning process.
- 29. The microstructure of claim 28 wherein the direct patterning process comprises depositing a radiation sensitive dielectric material on said substrate and selectively exposing the radiation sensitive dielectric material to radiation.
- 30. The microstructure of claim 27, wherein the patterned dielectric layer is formed by a solventless lithographic process.
- 31. The microstructure of claim 30, wherein the solventless lithographic process comprises using a supercritical fluid as a developer.
- 32. A microelectronic structure comprising:
a substrate; at least one transistor formed on the substrate; and at least one conductive two-dimensional feature formed within a dielectric pattern, wherein the conductive two-dimensional feature has a dimensional tolerance more precise than 7% of the dimension of the two-dimensional feature.
- 33. The microelectronic structure of claim 32, wherein the conductive feature further includes a plurality of transistors.
- 34. The microelectronic structure of claim 32 wherein the conductive feature comprise at least one metal line.
- 35. A microstructure comprising:
a substrate; and a three-dimensional structure formed on the substrate, wherein the three dimensional structure is formed by a three-dimensional direct patterning process.
- 36. The microstructure of claim 35 wherein the three-dimensional direct patterning process comprises depositing a radiation sensitive dielectric material on the substrate and selectively exposing the radiation sensitive dielectric material to radiation using a three-dimensional imaging technique.
- 37. The microstructure of claim 36 wherein the three-dimensional direct patterning process further comprises using a supercritical fluid as a developer.
- 38. The microstructure of claim 36 wherein the three-dimensional imaging technique comprises two-photon patterning.
- 39. The microstructure of claim 36 wherein the three-dimensional imaging technique comprises holographic imaging.
Parent Case Info
[0001] This invention was made in the course of research sponsored in part by the National Science Foundation. The U.S. Government may have certain rights in this invention.