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C045 node (65nm half pitch) technology processes are driving the development of immersion lithography techniques and infrastructures and C032 node (45nm half pitch) is following in its tracks. As semiconductor development enters the arena of low leakage, high-performance devices using immersion lithography, the 45nm hp technology adds more pressure of decreasing pitches and feature sizes using the most cost effective method available. The Crolles2 Alliance is in the first phases of the push for very low k1 193nm lithography for our technology development. Many resolution enhancement techniques are being explored to fill the low k1 realm; including implementation of these techniques and more aggressive integrations to support the device parameters. However, the early development of 45nm hp node along with the need for better focus and dose control algorithms, imaging of pitches to allow for the packing density will present significant challenges to photolithography even when considering super hyper-NA immersion lithography. Reflectivity variations, thin film interference through the complex film stacks, and increased sensitivity to feature size is posing a challenge for maintaining good and consistent features. This paper discusses an analysis and early results covering the beginning development of 45nm hp with >1NA immersion lithography. Specifically, parameters such as illumination and enhancement techniques, processing capability, application of OPC at a very low k1, process integration, mask effects, and defectivity as discussed.

The merits of hyper NA imaging using 193 nm exposure wavelength with water immersion for 45 nm and 32 nm nodes is clear. However, the challenge remains CD control at hyper NA and the development of ARC stacks to support not only lithographic response but also device integrations. Extreme off-axis illumination, polarization, and dense pitches of the C045 and C032 nodes show a significant degradation of reflection and CD control and a significant loss of resolution. Consequently, hyper NA patterning requires the development of a new ARC to improve the overall CD control. Thus, a single ARC layer could not ensure the reflectivity condition, and ARC stacks must now be decomposed into two or three components in order to suppress reflectivity through a wide range of incidence angle. In a previous work, we presented the advantage of using an antireflective based on CVD organic - inorganic stacks. This paper presents an upgrade of this type of stack, applied to 1.2NA imaging. We will show stack reflectivity simulations based on S-matrix approach. The capabilities of the CVD tools have been taken into account in the simulations in order to define a reflectivity process window. We will present 1.2NA lithography with different optimized ARC stacks, comparing potential capability and CD control in conjunction with the immersion lithography for 45 nm and 32 nm nodes.

The introduction of immersion lithography in the production phase has been accompanied with high level of defects compared to standard process on dry lithography. Continuous process optimization allowed us to reduce the defectivity to dry lithography level. This learning cycle also permitted to improve our knowledge on immersion defectivity formation. Immersion lithography process cause specific defects type as watermarks, bubbles, extra pattern and swelling of lines. We will report in this article on our latest experiment on the understanding of defects formation during immersion process. The influence of the track and scanner parameters has been investigated as well as materials issue (resist, topcoat). Measurements of leaching, receding contact angle and water uptake have been performed in order to correlate with defect formation. It appears that material, track and scanner parameters play different role on the formation of specific immersion defects.

This paper presents a cost-effective 45-nm technology platform, primarily designed to serve the wireless multimedia and consumer electronics needs. This platform features low power transistors operating at a nominal voltage of 1.1V, an ultra low k dielectric (k~2.5) with up to 9 Cu metal layers and 0.25/0.3/0.37mum2 SRAM cells. This platform also features an optional third gate oxide for either higher speed or active power mitigation. This technology has been developed on the (100)-oriented substrate with a key focus on process simplicity. Transistor improvement relies on mask-free strain engineering techniques along with co-implanted halos and laser anneal. The impact of laser anneal on transistor reliability and mixed-signal capabilities are also examined. Drive current as high as 660/320 muA/mum at 1nA/mum and 1.1V are reported

The semiconductor industry will soon be putting >=1.07NA 193nm immersion lithography systems into production for the 45nm device node and in about three years will be putting >=1.30NA systems into production for the 32nm device node. For these very high NA systems, the maximum angle of light incident on a 4X reticle will reach ~16 degrees and ~20 degrees for the 45nm and 32nm nodes respectively. These angles can no longer be accurately approximated by an assumption of normal incidence. The optical diffraction and thin film effects of high incident angles on the wafer and on the photomask have been studied by many different authors. Extensive previous work has also investigated the impact of high angles upon hard (e.g., F-doped silica) thick (>700μm) pellicles for 157nm lithography, e.g.,. However, the interaction of these high incident angles with traditional thin (< 1μm) organic pellicles has not been widely discussed in the literature. In this paper we analyze the impact of traditional thin organic pellicles in the imaging plane for hyper-NA immersion lithography at the 45nm and 32nm nodes. The use of existing pellicles with hyper-NA imaging is shown to have a definite negative impact upon lithographic CD control and optical proximity correction (OPC) model accuracy. This is due to the traditional method of setting organic pellicle thickness to optimize normally incident light transmission intensity. Due to thin film interference effects with hyper-NA angles, this traditional pellicle optimization method will induce a loss of high spatial frequency (i.e., high transmitted angle) intensity which is similar in negative impact to a strong lens apodization effect. Therefore, using simulation we investigate different pellicle manufacturing options (e.g., multi-layer pellicle films) and OPC modeling options to reduce the high spatial frequency loss and its impact.

In this work, we report on the integration of 30nm gate length CMOS devices fabricated using laser spike annealing (LSA). Considerably improved short channel effects and drive current (+10% Ion at constant Ioff for NMOS) are demonstrated on samples using LSA. Excellent IonIoff characteristics (Ion = 940 muA/mum Ioff = 200 muA/mum for NMOS and Ion = 390muA/mum Ioff = 50 nA/mum for PMOS at Vdd = 1 V) are measured that are at the leading edge of the state of the art. Moreover, an enhanced dynamic behavior (-6% in ring oscillator delay) and improved characteristics of high density SRAM bit-cells (+24% Icell for the same 1sb) are reported. These results demonstrate the potential of LSA in the perspective of 30 nm device integration of a 45 nm bulk CMOS platform

The merits of complementary double dipole illumination using 193 nm exposure wavelength with water immersion for 45 nm and 32 nm nodes is investigated. Off-axis dipole illumination shows a significant improvement in the resolution for lines and spaces oriented along the direction perpendicular to the dipole orientation. However, there is also a significant loss of resolution along the dipole direction. Consequently, two dimensional circuit patterning requires a double exposure to improve the resolution in both directions. Thus, the original layout must be decomposed into two masks: one containing the features to be primarily imaged with one dipole and another one with features to be imaged in the complementary direction. The horizontal and vertical lines must be selected and protective patches are required on each mask to protect the pattern formed by the complementary exposure. The potential capability of the dipole illumination used in conjunction with the immersion lithography for 45 nm and 32 nm nodes will be described. The Mentor Graphic approach based on the model assisted decomposition for the Double Dipole Lithography (DDL) was applied to the small clips of the 2D layout of the gate level for random logic. The lithographic process window and the CD control will be estimated through simulation.