This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2012-192568, filed on Aug. 31, 2012; the entire contents of which are incorporated herein by reference.
Embodiments described herein relate generally to a patterning method and a template.
Pattern transfer technology by imprinting is drawing attention as technology in the manufacturing processes of semiconductor devices to form fine patterns while being suitable for mass production. In imprinting, an imprint resist such as a liquid organic material, etc., is supplied onto a wafer; and the imprint resist is cured by, for example, light irradiation in the state in which a template including an unevenness pattern is caused to contact the imprint resist.
Although a method for aligning the template with the wafer has been proposed in which mark groups are pre-formed in the wafer and the pattern is transferred onto multiple shot regions while aligning the template with the mark groups, forming the mark groups to be aligned with the wafer with high precision leads to higher costs.
According to one embodiment, a patterning method includes causing a main pattern and an alignment pattern of a template to contact an imprint resist that is supplied onto a patterning body and uncured. The template has a mesa portion and a non-imprint portion provided to recede from the mesa portion in a region on an outer side of the mesa portion. The main pattern and the alignment pattern are formed as unevenness patterns in the mesa portion. The method includes curing the imprint resist in the state of the template being in contact to form a transfer pattern of the main pattern and a transfer pattern of the alignment pattern in the imprint resist. The method includes releasing the template from the cured imprint resist, aligning an alignment mark formed in the non-imprint portion of the template with the transfer pattern of the alignment pattern without causing the alignment mark to contact the imprint resist, and causing the main pattern and the alignment pattern of the template to contact an imprint resist that is supplied to a shot region adjacent to the cured imprint resist and uncured. The method includes curing the imprint resist of the adjacent shot region in the state of the template being in contact to form the transfer pattern of the main pattern and the transfer pattern of the alignment pattern in the imprint resist.
Embodiments will now be described with reference to the drawings. Similar components in the drawings are marked with like reference numerals.
For the template 20 shown in
In
The template 20 is formed in, for example, a plate configuration having a quadrilateral exterior configuration; and a mesa portion 21 is provided on one surface side. The planar configuration of the mesa portion 21 is a quadrilateral configuration; and a non-imprint portion 31 is provided in a region around the mesa portion 21. The mesa portion 21 protrudes from the non-imprint portion 31; and conversely, the non-imprint portion 31 recedes from the mesa portion 21.
The mesa portion 21 is provided in the region on the inner side of the template 20 including the surface-direction center; and the non-imprint portion 31 is provided in the region on the outer side of the mesa portion 21 in the surface direction. When the template 20 is viewed in plan from the side of the surface where the mesa portion 21 is provided, the non-imprint portion 31 is provided continuously around the mesa portion 21.
The template 20 is made of a material (e.g., quartz) that is transmissive to light (e.g., ultraviolet light) that cures an imprint resist 11 described below. The mesa portion 21 and the non-imprint portion 31 are provided as a single body.
The main pattern 23 and the alignment patterns 25 are formed at the front surface of the mesa portion 21. Both the main pattern 23 and the alignment patterns 25 are formed as unevenness patterns.
As shown in
The main pattern 23 is formed in the region on the inner side of the four alignment patterns 25. The main pattern 23 is a pattern corresponding to the circuit pattern of the semiconductor device and has multiple recesses and multiple protrusions that are repeated at a fine pitch corresponding to the circuit pattern.
The alignment marks 35 are formed as unevenness patterns in the non-imprint portion 31. The protrusions of the unevenness patterns included in the alignment marks 35 do not protrude higher than the mesa portion 21.
Multiple alignment marks 35 are formed in the non-imprint portion 31; and one alignment mark 35 has, for example, four recesses 32 having bar configurations combined in a quadrilateral configuration.
The alignment patterns 25 are formed in the end portion region of the mesa portion 21 between the main pattern 23 and the alignment marks 35.
Here, two orthogonal directions in a plane parallel to the front surface of the mesa portion 21 are taken as an X direction (a first direction) and a Y direction (a second direction).
For the front surface of the mesa portion 21 as shown in
Also, for the front surface of the mesa portion 21, two alignment patterns 25 are arranged in the Y direction in a region on one end side in the X direction; and two alignment patterns 25 also are arranged in the Y direction in a region on the other end side in the X direction.
As shown in
In each of the region 31a and the region 31b, two alignment marks 35 are arranged at a pitch corresponding to the pitch of the alignment patterns 25 in the X direction.
In each of the region 31c and the region 31d, two alignment marks 35 are arranged at a pitch corresponding to the pitch of the alignment patterns 25 in the Y direction.
Accordingly, eight alignment marks 35 are formed in the non-imprint portion 31. Each of the alignment marks 35 is formed proximally to a corner of the mesa portion 21.
One alignment mark 35 and one alignment pattern 25 are used to form a bar-in-bar combination. As described below with reference to
Because the pitch of the alignment marks 35 in the Y direction corresponds to the pitch of the alignment patterns 25 in the Y direction, it is possible for two alignment marks 35 arranged in the Y direction to be contained simultaneously inside the alignment transfer patterns 42 as shown in
Also, because the pitch of the alignment marks 35 in the X direction corresponds to the pitch of the alignment patterns 25 in the X direction, it is possible for two alignment marks 35 arranged in the X direction to be contained simultaneously inside the alignment transfer patterns 42 as shown in
The pitch of the unevenness of the alignment pattern 25 and the pitch of the unevenness of the alignment mark 35 are larger than the minimum pitch of the unevenness of the main pattern 23. Therefore, the transfer patterns (the alignment transfer patterns) 42 of the alignment patterns 25 and the alignment marks 35 overlaid on the alignment transfer patterns 42 can be easily detected optically using a camera, etc.
The patterning method according to the first embodiment will now be described with reference to
As shown in
The imprint resist 11 is supplied to each region (shot region) that is multiply divided in the surface of the wafer 10. Then, as described below, the imprint resist 11 is cured in the state in which the template 20 is caused to contact the uncured imprint resist 11 to transfer the main pattern 23 and the alignment patterns 25 formed in the template 20 onto the imprint resist 11.
When the imprint for one shot region ends, the uncured imprint resist 11 is newly supplied to one other shot region adjacent to the one shot region; the template 20 is caused to contact the imprint resist 11; and the imprint resist 11 is cured. Then, the uncured imprint resist 11 is further supplied to a shot region adjacent to the one other shot region; and the procedure is repeated. In other words, the pattern of the template 20 is transferred onto multiple shot regions of the front surface of the wafer 10 by a step-and-repeat method.
After the imprint resist 11 is supplied to one shot region, the main pattern 23 and the alignment patterns 25 formed in the mesa portion 21 of the template 20 are caused to contact the uncured imprint resist 11 as shown in
The uncured imprint resist 11 is filled into the recesses of the main pattern 23, the recesses of the alignment patterns 25, and a recess 24 between the main pattern 23 and the alignment patterns 25.
At this time, the non-imprint portion 31 which is provided to recede from the mesa portion 21 does not contact the imprint resist 11.
Then, the imprint resist 11 is cured in the state shown in
Or, a thermosetting resin may be used as the imprint resist 11; and the imprint resist 11 may be cured by heating. In such a case, the template 20 may not be light-transmissive.
After the imprint resist 11 is cured, the template 20 is released from the imprint resist 11 as shown in
A main transfer pattern 41 where the unevenness of the main pattern 23 of the template 20 is inverted and the alignment transfer patterns 42 where the unevenness of the alignment patterns 25 of the template 20 is inverted are formed in the cured imprint resist 11. The alignment transfer patterns 42 are formed in the end portion region of the shot region.
Then, as shown in
Then, the alignment marks 35 formed in the non-imprint portion 31 of the template 20 are overlaid on the imprinted alignment transfer patterns 42 formed in the end portion region of the adjacent shot region above the alignment transfer patterns 42 in non-contact with the alignment transfer patterns 42.
A camera 52 is provided above the template 20; and the positions of the alignment marks 35 and the positions of the alignment transfer patterns 42 are optically detected by the camera 52.
A detection signal is sent to a controller 53; and the controller 53 corrects the relative positions of the wafer 10 and the template 20 by moving one or both of a stage 51 that supports the wafer 10 and the template 20 if necessary based on the detection signal. The template 20 and the wafer 10 are moved relatively in the X direction or the Y direction shown in
In the case where the imprinted shot region and the next shot region to be imprinted are adjacent in the X direction as shown in
Or, in the case where the imprinted shot region and the next shot region to be imprinted are adjacent in the Y direction as shown in
In the case where the shot region to be imprinted is respectively adjacent in the X direction and the Y direction to two previously-imprinted shot regions, the alignment marks 35 are aligned with the alignment transfer patterns 42 between the shot region to be imprinted and the imprinted shot region adjacent in the X direction such that two alignment marks 35 arranged in the Y direction in the non-imprint portion 31 of the template 20 are contained respectively on the inner sides of two alignment transfer patterns 42 already formed in the end portion region of the imprint resist 11 and arranged in the Y direction. And the alignment marks 35 are aligned with the alignment transfer patterns 42 between the shot region to be imprinted and the imprinted shot region adjacent in the Y direction such that two alignment marks 35 arranged in the X direction in the non-imprint portion 31 of the template 20 are contained respectively on the inner sides of two alignment transfer patterns 42 already formed in the end portion region of the imprint resist 11 and arranged in the X direction.
The template 20 is aligned with the imprinted shot region by the alignment marks 35 of the template 20 being aligned with the alignment transfer patterns 42 formed in the imprinted shot region. The imprint resist 11 of the adjacent shot region is patterned using the template 20. As a result, two main transfer patterns 41 transferred respectively onto two adjacent shot regions using the template 20 have an orderly arrangement at the desired distance (pitch).
Further, because multiple pairs (in the embodiment, two pairs) of the combined pair of the overlaid alignment mark 35 and alignment transfer pattern 42 are arranged in each of the X direction and the Y direction, the tilt (the rotation) in the XY plane of the template 20 with respect to the shot regions also can be corrected.
Then, the alignment marks 35 are overlaid on the alignment transfer patterns 42; the state in which the template 20 is aligned with the wafer 10 is maintained; and the main pattern 23 and the alignment patterns 25 formed in the mesa portion 21 of the template 20 are caused to contact the uncured imprint resist 11 supplied to the shot region now being imprinted as shown in
At this time as well, the non-imprint portion 31 provided to recede from the mesa portion 21 does not contact the imprint resist 11. The mesa portion 21 formed in the region on the inner side of the non-imprint portion 31 in the surface direction of the template 20 does not overlap the cured imprint resist 11 of the adjacent imprinted shot region.
Accordingly, the template 20 does not physically interfere with the main transfer pattern 41 and the alignment transfer patterns 42 already formed in the imprint resist 11 of the imprinted shot region when imprinting one other adjacent shot region.
In the template 20, the alignment patterns 25 are formed in the end portion region of the mesa portion 21 between the main pattern 23 and the alignment marks 35. Therefore, the transfer patterns (the alignment transfer patterns) 42 of the alignment patterns 25 are formed in the end portion region of the shot region. Accordingly, the alignment marks 35 formed in the non-imprint portion 31 can be overlaid on the alignment transfer patterns 42 while suppressing the increase of the protruding width of the non-imprint portion 31 in the surface direction.
As shown in
Then, in the state in which the template 20 contacts the imprint resist 11, the imprint resist 11 is cured by irradiating the ultraviolet light 100 through the template 20 onto the imprint resist 11 from above the template 20 as shown in
After the imprint resist 11 is cured, the template 20 is released from the imprint resist 11 as shown in
Then, the imprint resist 11, onto which the transfer pattern (the main transfer pattern) 41 of the main pattern 23 and the transfer patterns (the alignment transfer patterns) 42 of the alignment patterns 25 of the template 20 are transfer-formed, is formed in all of the shot regions by repeating the processes described above for each of the shot regions.
Subsequently, unevenness patterns 71 and 72 are formed at the front surface of the wafer 10 by performing etching of the wafer 10 as shown in
The unevenness pattern 71 formed under the main transfer pattern 41 of the imprint resist 11 corresponds to the circuit pattern of the semiconductor device and includes an unevenness that is repeated at a fine pitch.
The unevenness patterns 72 formed under the alignment transfer patterns 42 of the imprint resist 11 are formed in a region corresponding to the dicing region and do not remain in the semiconductor chip singulated by dicing. Or, the unevenness patterns 72 remain in the semiconductor chip after the singulation but do not function as circuits.
According to the embodiment described above, the transfer pattern (the main transfer pattern) 41 of the main pattern 23 formed in each of the multiple shot regions has an orderly arrangement at the desired spacing (pitch) by using the template 20 that has the mesa portion 21 including the alignment patterns 25 to be transferred with the main pattern 23 onto the imprint resist 11 and the non-imprint portion 31 including the alignment marks 35 that are aligned with the transfer patterns (the alignment transfer patterns) 42 of the alignment patterns 25 without pre-forming mark groups with high positional precision on the wafer 10. The cost can be reduced because it is unnecessary to form the mark groups that are aligned with the wafer 10 with high precision.
A patterning method according to a second embodiment will now be described.
In the second embodiment as well, the transfer patterns (the alignment transfer patterns) 42 of the alignment patterns 25 and the transfer pattern (the main transfer pattern) 41 of the main pattern 23 formed in the template 20 are formed in the imprint resist 11 by curing the imprint resist 11 in the state in which the template 20 is caused to contact the uncured imprint resist 11 supplied to each of the shot regions using a template 20 similar to that of the first embodiment.
In the first embodiment, the imprinting is repeated by aligning the alignment marks 35 of the template 20 with the alignment transfer patterns 42 formed in the imprint resist 11 of the adjacent imprinted shot region each time the imprinting of the shot region is performed.
Conversely, in the second embodiment, the imprinting is repeated by aligning the position of the template 20 with each of the shot regions of the wafer 10 front surface by a relative movement control between the wafer 10 and the template 20.
However, in the case where the imprinted alignment transfer patterns 42 already are formed adjacently to the shot region now being imprinted, the positions of the alignment transfer patterns 42 and the positions of the alignment marks 35 of the template 20 above the alignment transfer patterns 42 are detected by the camera 52 shown in
From the detection result, the controller 53 shown in
Then, when performing the imprinting of the next wafer 10 using the template 20, the controller 53 aligns the template 20 with each of the shot regions of the wafer 10 by controlling the relative movement between the stage 51 and the template 20 based on the correction parameter recited above that is read from the memory device 54.
By providing the correction data of the alignment between the wafer 10 and the template 20 obtained when imprinting the previous wafer 10 as feedback for the relative movement control of the template 20 for the next wafer 10, the multiple patterns can be transferred in an orderly arrangement with high precision.
According to the second embodiment, it is unnecessary to finely adjust the relative positions of the stage 51 and the template 20 for each shot such that the alignment marks 35 have the desired overlapping state with respect to the alignment transfer patterns 42; and the imprint processing can be performed with a high throughput.
The correction data recited above may be renewed for the imprint processing of each of the wafers 10; or the same correction data may be used for a number of multiple wafers 10 (e.g., the multiple wafers 10 of the same lot).
The combination of the alignment mark 35 and the alignment pattern 25 is not limited to the bar-in-bar type, and may be a box-in-box type as shown in
In the box-in-box type shown in
For the line-and-space types shown in
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modification as would fall within the scope and spirit of the inventions.
Number | Date | Country | Kind |
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2012-192568 | Aug 2012 | JP | national |