The present invention relates to cleaning photomasks used in photolithography processes. More particularly, this invention relates to methods for cleaning photomasks using quaternary ammonium hydroxides and the chemical solutions used in such methods.
Photolithography, also known as simply “lithography,” is commonly used in the formation of microelectronic devices (e.g., semiconductor devices) and other structures on wafers or other substrates. In general, a surface is coated with a resist (or photoresist), and light is projected onto the resist through a mask, or reflected by the mask onto the surface. Depending on the type of resist used, the light causes alterations in the chemical structures of the resist, which upon the application of a developer either allows the exposed portions of the resist to be removed or prevents the exposed portions of the resist from being removed. Once a portion of the resist is removed, the exposed substrate surfaces may be etched or otherwise processed.
In recent years, extreme ultraviolet (EUV) lithography has become increasingly used due to some of the limitations associated with conventional (e.g., optical) lithography. EUV lithography often utilizes electromagnetic radiation having a wavelength of between, for example, 10 nanometers (nm) to 124 nm, which interacts with various optics, such as condensers, lenses, and mirrors, and is projected onto a photomask (or mask) and reflected onto the coated surface of the substrate. The process is often performed in a controlled atmosphere environment (e.g., a vacuum)
During the process, various materials, such as organic compounds, may be liberated from the resist, or unintentionally brought into the process chamber as contaminants, and deposited onto various components in the system including the photomask, in the form of, for example, carbon residue. This residue, or other particles and foreign material, may cause defects in the optics and mask that may negatively affect the performance of the process.
EUV photomasks are relatively complicated and expensive to manufacture. Thus, it is desirable to be able to reuse the masks as much as possible before they are replaced with new masks. In order to maintain suitable performance, the masks must be intermittently cleaned to remove the carbon residue and any other particles or foreign material. Conventional cleaning methods typically involve the use of a sulfuric acid/hydrogen peroxide mixture (SPM), perhaps in combination with mechanical processes (e.g., brushing) and/or ultrasonic energy. The SPM-type chemistries are highly oxidative and tend to damage the masks, in particular, the ruthenium capping layer, and affect the critical dimensions of the masks, thus shortening their service life.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The drawings are not to scale and the relative dimensions of various elements in the drawings are depicted schematically and not necessarily to scale.
The techniques of the present invention can readily be understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
A detailed description of one or more embodiments is provided below along with accompanying figures. The detailed description is provided in connection with such embodiments, but is not limited to any particular example. The scope is limited only by the claims, and numerous alternatives, modifications, and equivalents are encompassed.
Numerous specific details are set forth in the following description in order to provide a thorough understanding. These details are provided for the purpose of example and the described techniques may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the embodiments has not been described in detail to avoid unnecessarily obscuring the description.
The term “horizontal” as used herein will be understood to be defined as a plane parallel to the plane or surface of the substrate, regardless of the orientation of the substrate. The term “vertical” will refer to a direction perpendicular to the horizontal as previously defined. Terms such as “above”, “below”, “bottom”, “top”, “side” (e.g. sidewall), “higher”, “lower”, “upper”, “over”, and “under”, are defined with respect to the horizontal plane. The term “on” means there is direct contact between the elements. The term “above” will allow for intervening elements.
Embodiments described herein provide methods for cleaning photomasks (or masks) used in photolithography, such as extreme ultraviolet (EUV) lithography, and the chemical solutions used in such methods. In some embodiments, the chemical solutions include one or more quaternary ammonium hydroxide. The quaternary ammonium hydroxide(s) includes, for example, tetraethyl ammonium hydroxide (TEAH), tetrapropyl ammonium hydroxide (TPAH), or a combination thereof.
In some embodiments, the chemical solutions also include a surfactant. The surfactant may include t-octylphenoxypolyethoxyethanol, trimethylnonylpolyethylene glycol, or a combination thereof. In some embodiments, the chemical solutions also include diethylenetriamine (DETA), n-methyl-2-pyrrolidone (NMP), or a combination thereof (e.g., as a corrosion inhibitor).
Experimental data shows that these chemical solutions are effective at removing carbon residue. Additionally, the non-oxidative chemistry of the solutions does not cause the damage to the masks associated with conventional SPM chemistries, such as damage to the ruthenium layer with respect to the thickness, roughness, and extreme ultraviolet reflectance (EUVR) and damage to the absorber layer causing changes in critical dimensions. As a result, the service life of the masks are extended.
In some embodiments, the multi-layer stack 104 is formed on a side of the substrate 102 opposite the backing layer 110. The multi-layer stack 104 may include a series of alternating layers of molybdenum and silicon, with each of the individual layers having a thickness of, for example, between about 2 nanometers (nm) and 5 nm (e.g., about 3 nm thick molybdenum layers and about 4 nm thick silicon layers). Although only six layers are shown in the multi-layer stack in
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The absorber layer 108 is formed above the capping layer 106. In some embodiments, the absorber layer 108 includes (e.g., is made of) tantalum, tantalum nitride, tantalum nitride oxide, tantalum-boron oxide, tantalum-boron nitride, or a combination thereof and may have a thickness of, for example, between about 50 nm and about 75 nm. As is shown in
The backing layer 110 is formed on the side of the substrate 102 opposite the multi-layer stack 104. The backing layer 110 may be made of a conductive material to allow for electrostatic chucking of the photomask 100 during the photolithography process. In some embodiments, the backing layer 110 is made of chromium nitride and may have a thickness of, for example, between about 70 nm and about 100 nm.
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In some embodiments described herein, the carbon residue is at least partially removed using by exposing the photomask 100 to a chemical (or cleaning) solution that includes at least one quaternary ammonium hydroxide. In some embodiments, the quaternary ammonium hydroxide includes tetraethyl ammonium hydroxide (TEAH), tetrapropyl ammonium hydroxide (TPAH), or a combination thereof. It should be understood that in at least some embodiments the chemical solutions include water (e.g., deionized water) in addition to the various components described. Thus, in some embodiments, the chemical solution includes (e.g., comprises) at least one quaternary ammonium hydroxide and water.
In some embodiments, the chemical solutions also include a surfactant. The surfactant may include t-octylphenoxypolyethoxyethanol (e.g., TRITON X-100 available from Dow Chemical Company of Midland, Michigan), trimethylnonylpolyethylene glycol (e.g., TERGITOL TMN-10 or TERGITOL 15-S-9 available from Dow Chemical Company of Midland, Mich.), or a combination thereof. Thus, in some embodiments, the chemical solution includes (e.g., comprises) at least one quaternary ammonium hydroxide, a surfactant, and water.
In some embodiments, the chemical solutions also include a corrosion inhibitor. The corrosion inhibitor may include diethylenetriamine (DETA), n-methyl-2-pyrrolidone (NMP), or a combination thereof. Thus, in some embodiments, the chemical solution includes (e.g., comprises) at least one quaternary ammonium hydroxide, a surfactant, a corrosion inhibitor, and water.
In some embodiments, the photomask 100 is exposed to the chemical solution by, for example, spraying the chemical solution onto the photomask 100, submerging the photomask 100 in the chemical solution (e.g., a bath treatment), or a combination thereof. Before, during, and/or after the exposure to the chemical solution, mechanical processes (e.g., brushing) and/or ultrasonic energy may also be applied to facilitate the removal of the carbon residue. In some embodiments, the photomask 100 is exposed to the chemical solution with the chemical solution at room temperature (e.g., about 21° C.), while in some embodiments, the chemical solution is heated to about 80° C.
In some embodiments, the chemical solution includes not more than about 20 mass % of the quaternary ammonium hydroxide (e.g., TEAH and/or TPAH), preferably not more than about 15 mass % of the quaternary ammonium hydroxide. For example, in some embodiments, the chemical solution includes about 15 mass % TEAH or about 10 mass % TPAH.
In some embodiments, the chemical solution also includes not more than about 5 mass % of the surfactant (e.g., t-octylphenoxypolyethoxyethanol and/or trimethylnonylpolyethylene glycol), preferably not more than about 2 mass % of the surfactant. For example, in some embodiments, the chemical solutions includes about 1 mass % t-octylphenoxypolyethoxyethanol or trimethylnonylpolyethylene glycol.
In some embodiments, the chemical solution also includes not more than about 20 mass % of the corrosion inhibitor (e.g., DETA and/or NMP). For example, in some embodiments, the chemical solution includes about 20 mass % NMP. In some embodiments, the chemical solution includes not more than about 1 mass % of the corrosion inhibitor. For example, in some embodiments, the chemical solution includes about 0.1 mass % DETA.
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At block 3704, a photolithography process is performed using the photomask. In some embodiments, the photolithography process includes projecting electromagnetic radiation (e.g., in the ultraviolet range) onto the photomask, where it may be selectively reflected by the portions of the photomask that do not have the absorber layer formed thereon. In some embodiments, during the photolithography process, residue, such as carbon residue, is deposited or builds up on various portions of the capping layer and/or the absorber layer. It should be noted that in some embodiments, the provided photomask may have been previously used in a photolithography process and thus already have carbon residue deposited thereon. As such, block 3704 may be omitted in some embodiments.
At block 3706, the photomask is exposed to a chemical solution to at least partially remove the carbon residue. The chemical solution includes at least one quaternary ammonium hydroxide, such as TEAH, TPAH, or a combination thereof. In some embodiments, the chemical solutions also include a surfactant. The surfactant may include t-octylphenoxypolyethoxyethanol, trimethylnonylpolyethylene glycol, or a combination thereof. In some embodiments, the chemical solutions also include DETA, NMP, or a combination thereof (e.g., as a corrosion inhibitor).
At block 3710, the method ends. In some embodiments, after the photomask is exposed to the chemical solution (and/or after block 3710), the photomask is again used in one or more photolithography processes as described above.
Thus, in some embodiments, methods are provided. A photomask is provided. The photomask is exposed to a chemical solution. The chemical solution includes a quaternary ammonium hydroxide.
The photomask may be an EUV lithography photomask. The quaternary ammonium hydroxide may include at least one of TEAH, TPAH, or a combination thereof. The photomask may include ruthenium. The photomask may further include tantalum, molybdenum, and silicon.
The photomask may include a substrate. A multi-layer stack maybe formed above the substrate. The multi-layer stack may include a plurality of alternating first and second layers. The first layers may include molybdenum, and the second layers comprising silicon. A capping layer may be formed above the multi-layer stack. The capping layer may include ruthenium. An absorber layer may be formed above the capping layer. The absorber layer may include tantalum.
The chemical solution may further comprises a surfactant. The surfactant may include at least one of t-octylphenoxypolyethoxyethanol, trimethylnonylpolyethylene glycol, or a combination thereof. The chemical solution may further include at least one of DETA, NMP, or a combination thereof.
In some embodiments, methods for cleaning a photomask are provided. A photomask is provided. The photomask may include ruthenium, tantalum, molybdenum, and silicon. The photomask is exposed to a cleaning solution. The cleaning solution includes a quaternary ammonium hydroxide and a surfactant.
In some embodiments, chemical solutions for cleaning an EUV lithography photomask including comprising ruthenium are provided. The chemical solutions consist of a quaternary ammonium hydroxide, a surfactant, at least one of diethylenetriamine (DETA), n-methyl-2-pyrrolidone (NMP), or a combination thereof, and water.
Although the foregoing examples have been described in some detail for purposes of clarity of understanding, the invention is not limited to the details provided.
There are many alternative ways of implementing the invention. The disclosed examples are illustrative and not restrictive.
This application claims priority to U.S. Provisional Application No. 62/149,847, filed on Apr. 20, 2015, which is herein incorporated by reference for all purposes.
Number | Date | Country | |
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62149847 | Apr 2015 | US |