Method for Making a Photomask With Multiple Absorption Levels

1. Field of the Invention

The present invention relates generally to the manufacture and use of a photomask used in photolithographic processes during the manufacture of integrated circuits. More particularly, the present invention is directed to a photomask offering controllable multiple radiation-absorption levels and to a method for manufacturing the photomask.

2. Description of the Related Art

Certain integrated circuit fabrication processes require precise delimitation of areas to be affected by the fabrication process and of areas to be protected from the fabrication process. Photomasks are patterned masks used in photolithographical processes for selectively inhibiting the exposure to radiation, such as light, specific regions of a material to be patterned, while allowing radiation to act on other regions.

Conventional photomasks include a patterned layer of a light-blocking material, usually chromium, used to block transmission of the particular form of light used. Conventional chromium masks generally provide only one level of complete absorption--that is, light is either totally blocked by the chromium or transmitted in those regions from which the chromium has been removed. These "on-off" photomasks are referred to as binary intensity masks (BIM).

The exposure level of the photoresist, which is the material to be patterned using the photomask, can be controlled by raising or lowering the illumination level. This procedure causes all features defined by the photomask to receive approximately the same light exposure. To provide greater versatility in the exposure of photoresist patterns, particularly in the submicron regime, it would be desirable to have some features that receive relatively greater or less exposure than other features. For example, it is generally helpful if larger features receive less exposure than small features. Of course, it is possible to vary the exposure levels by using separate photomasks and repeating the exposure process. However, this repetitive process is impractical, requiring additional masks and additional exposure and development steps.

As an alternative to existing BIM photomasks, photomasks have been prepared which function to phase-shift the light energy. The basic principle of such masks is to use a phase-shifting material to interfere with the electric fields of light passing through adjacent open features and, thus, cause the annihilation of superimposed fields with opposite phases. One type of phase-shifting photomask, an attenuated phase-shifting mask (APSM), uses a film of a slightly transmissive absorber with a 180.degree. phase shift. By controlling the thickness and optical properties of the mask, such as by changing the chemical content of the film, two levels of light-transmission can be achieved in a single mask.

However, phase-shifting systems provide only limited control of absorption levels and require complex manufacturing processes. Additionally, researchers of phase-shifting systems have encountered difficulties applying such systems to arbitrary mask patterns and obtaining accurate feature delineation.

In view of the problems described above, a need remains for a photomask which can be efficiently manufactured and which offers multiple absorption levels. Accordingly, there is provided herein a photomask and method of its use which allows different portions of the photoresist to be exposed simultaneously to various levels of exposure using a single exposure process.

In accordance with one aspect of the present invention, there is provided a semiconductor manufacturer mask. The mask includes a plurality of radiation-absorbing layers. At least one etch-stop layer is disposed between the radiation absorbing layers.

In accordance with another aspect of the present invention, there is provided a semiconductor manufacturer mask having multiple light-absorption levels. The mask includes a plurality of light-absorbing layers. At least one etch-stop layer is disposed between the light-absorbing layers.

In accordance with yet another aspect of the present invention, there is provided a method for manufacturing a photomask having multiple light-absorbing levels. A photomask substrate is provided. A plurality of alternating layers of a light-absorbing material and of an etch-stop material are formed on the photomask substrate. The light-absorbing material and the etch-stop material are selectively etchable in relation to each other.

In accordance with still another aspect of the present invention, there is provided a method for manufacturing a photomask having multiple light-absorbing levels. A photomask substrate is provided. A first layer of a generally light-absorbing material is deposited onto the substrate. A second layer of a buffer material is formed onto the first layer. The second layer of buffer material is selectively etchable relative to the first layer. A third layer of a generally light-absorbing material is deposited. The third layer is selectively etchable relative to the second layer.

In accordance with a further aspect of the present invention, there is provided a method for patterning a semiconductor device. A photomask substrate is provided. A plurality of alternating layers of a light-absorbing material and of an etch stop material is formed on the photomask substrate. The layers are successfully patterned by removing at least a portion of at least one of the layers by selective etching process to form a photomask. A semiconductor wafer is provided. A photoresist is applied to at least a portion of the surface of the semiconductor wafer. The photomask is aligned over at least a portion of the photoresist. The photomask is exposed to light. The photoresist is developed.

In accordance with a still further aspect of the present invention, there is provided a method for manufacturing a semiconductor device. A photomask is provided. The photomask includes the plurality of selectively patterned light-absorbing layers. A semiconductor wafer under fabrication is provided. The wafer has a layer of photoresist at least partially over the wafer. The semiconductor wafer is exposed to light through the photomask. The photoresist is developed.

In accordance with a yet further aspect of the present invention, there is provided a method for patterning a semiconductor device. A photomask is provided. The photomask includes a substrate element. A first layer of a generally light-absorbing material is supported by the substrate. The first layer is over at least a first portion of the substrate. A buffer layer is over the first layer. A second layer of a generally light-absorbing material is supported over the buffer layer. The second layer is over a second portion of the substrate. The second portion is a substrate of the first portion. A semiconductor wafer under fabrication is provided. The wafer has a layer of photoresist at least partially over the wafer. The semiconductor wafer is exposed to light through the photomask. The photoresist is developed.

The foregoing and other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 depicts a portion of a photomask blank manufactured in accordance with the present invention, illustrated in vertical section;

FIG. 2 depicts the photomask blank of FIG. 1 during an intermediate manufacturing step, also illustrated in vertical section;

FIG. 3 depicts a photomask manufactured from the photomask blank of FIG. 1 including a multi-tiered photomask pattern, again illustrated in vertical section;

FIG. 4 depicts an alternative embodiment of a photomask manufactured in accordance with the present invention, again illustrated in vertical section; and

FIG. 5 is a schematic representation of the photomasking process for the manufacture of a semiconductor device.

Described below is a photomask having multiple radiation-absorption levels. The photomask may be utilized with optical photolithography systems and provide multiple absorption layers relative to a light-radiation surface. The photomask may be used with other types of radiation, including infrared and ultraviolet, and other radiation masking lithography operations wherein selective control of degree of radiation transmission through a mask is of benefit to the operation. The photomark is a composite multi-layered structure, including a plurality of superimposed light-absorbing material layers and etch-stop material layers. The multi-layered structure is manufactured by alternatively forming the layers over a photomask substrate, each etch-stop material layer placed between two relatively light-absorbing material layers.

Turning now to the drawings, FIG. 1 illustrates an exemplary embodiment of a photomask blank assembly 10 manufactured in accordance with the present invention. Photomask blank 10 includes three layers, 12, 14, and 16 of a generally light-absorbing material. Placed between the light-absorbing material layers 12, 14, and 16 are relatively thinner layers 20 and 22 of an etch-stop or buffer material. This buffer material is selected depending upon the etch process for the selected light-absorbing material. The term "light" as used herein is meant to include radiation having wavelengths in the visible spectrum, infrared, ultraviolet, deep ultraviolet regions (including G, H, and I-line wavelength radiation), and X-ray regions. Photomasks described herein may be utilized with these and other forms of radiation used in optical photolithography techniques or techniques wherein exposure may be controlled through absorbing or blocking the radiation. "Light-absorbing" as used herein is meant to define a material which, for the resist exposure wavelengths used in the selected photolithography technique, absorbs or reflects at least a portion of the light impinging the surface of the material. The term, thus, expressly includes materials which partially transmit light.

Light-absorbing layers 12, 14, and 16 are supported by an appropriate support surface 11, such as a quartz plate, soda-lime glass, borosilicate glass, or other suitable surface. Other suitable photomask substrate materials known in the art, such as sapphire, may also be used. Support surface 11 may be selected in accordance with properties that have acceptable transmission thermal expansion and optical transmission characteristics for the specific application.

Selection of an appropriate light-absorbing material is generally based on physical characteristics, optical properties, and etching selectivity. A particularly advantageous material may exhibit relatively high coefficients of hardness and toughness to reduce the possibility of scratching or deformation of the photomask. The desired transmission and absorption coefficient of the material may depend, among other factors, upon the range of the desired absorption levels of the finished photomask. Finally, the light-absorbing material may be selected as having a well-defined etching selectivity relative to the etch-stop material for a satisfactory etchant.

While factors such as optical properties, chemical compatibility, and ease of deposition may also affect the selection of the material for the interlaced etch-stop layers, a principal factor is the ability of the material to act as an etching barrier during the etching of the light-absorbing material layers. Likewise, the light-absorbing material can act as an etch barrier during removal or patterning of the etch-stop layers.

An exemplary preferred light-absorbing/etch-stop material pair, used in the embodiment illustrated in FIG. 1, is amorphous silicon and silicon dioxide. Chromium and silicon dioxide could also be utilized as the light absorbing/etch-stop material pair, potentially in combination with one or more layers of amorphous silicon. Other possible light-absorbing materials are titanium, titanium nitride, tungsten and molybdenum. Other suitable material pairs or groupings may also be used.

To manufacture photomask 10, an appropriate photomask support surface 11 is first provided. Support surface 11 is originally prepared by cutting glass or quartz plates from large sheets. In a conventional manner, the plates are cleaned to remove chips and graded for flatness. The plates are further polished, cleaned, and inspected before the application of the first light-absorbing layer 12. Alternate layers of light-absorbing material 12, 14, and 16 and etch-stop material 20 and 22 are then formed over the support surface 11. One method of deposition of an amorphous silicon light-absorbing layer 12, 14, or 16 may be low pressure chemical vapor deposition (LPCVD) conducted at temperatures generally below 580.degree. C. The SiO.sub.2 etch-stop layers 20 and 22 may be deposited using low temperature deposition of SiO.sub.2, such as in an atmospheric pressure CVD reactor (APCVD) or in a plasma-enhanced CVD reactor (PECVD).

In most processes, it is important that the SiO.sub.2 deposition occur generally below approximately 580.degree. C. so as to preserve the amorphous state of the deposited silicon layer(s). Although the thickness of the layers may vary depending on the selected light spectrum and exposure time, the thickness for the amorphous silicon layers 12, 14, and 16 of the present embodiment is 300-800A, and the thickness for the SiO.sub.2 layers 20 and 22 of the present embodiment is 100-500A.

FIG. 2 illustrates a step in the manufacture of photomask 10 wherein layers 12, 20, and 14 have been formed successively over supporting surface 11 using a deposition process or other suitable method. The number of light-absorbing and etch-stop layers can be readily altered in alternative embodiments. Generally, for every n layers of light-absorbing material, there will be n-1 layers of etch-stop material. The number of layers is determined by the desired number of absorption levels. In general, n layers of silicon with n-1 intervening layers of silicon oxide will provide for at least n+1 possible absorption or exposure levels. More absorption levels are possible (2n), if the intermediate etch-stop layer also comprises a suitable light-absorbing material.

Together the layers 12, 14, 16, 20, and 22 form a composite multi-layered structure. Upon formation of the last layer, the photomask blank 10 can be patterned by removing portions 23 and 25 of one or more layers along selected regions in response, for example, to the size of the features being defined. FIG. 3 illustrates a photomask 110 manufactured from the photomask blank 10 shown in FIG. 1.

In the present embodiment, to pattern photomask blank 10 into photomask 110, portions of one or more layers along selected regions are successively and selectively removed by repeated etching steps. The higher layers, that is, the layers farthest from the support surface 11, can serve, at least partly, as masks for the patterning of the lower layers. Alternatively, the layer immediately below a layer which is being etched, acts as an etching barrier to prevent damage to underlying layers. The photomask 110 can be patterned to have a positive polarity (clear-field) or a negative polarity (dark-field). Dry etching is a preferred removal method, although wet etching or other suitable methods can also be utilized. In the embodiment pictured in FIG. 3, the layers 12, 14, and 16 of amorphous silicon may be removed, for example, using plasma etching by an etchant including chlorine and/or bromine containing gases, with or without diluent neutral gases. The silicon oxide layers 20 and 22 can be etched using a fluorine containing gas, such as CF.sub.4, C.sub.2 F.sub.6, or C.sub.3 F.sub.8, and possibly hydrogen containing gas, such as CHF.sub.3, to aid etching selectivity.

The levels of absorption of different regions of photomask 110 can be precisely controlled by controlling the removal of layers along those regions. In the depicted embodiment, with three layers 12, 14, and 16 of amorphous silicon, photomask 110 can provide at least four different levels of exposure. All layers are removed along those regions where maximum exposure is desired (e.g., region D). Conversely, regions where the least exposure (and maximum photomask light-absorption) is desired would be those where all three layers 12, 14, and 16 are left intact (e.g., region A). Intermediate exposure levels can be accomplished by removing one layer 16 (e.g., region B) or two layers 14 and 16 (e.g., region C) of the amorphous silicon, along with none, one, or two of the intervening silicon oxide layers 20 and 22. Each layer of light-absorbing material 12, 14, and 16 and an associated etch-stop layer 20 and 22 can be selectively removed if desired in accordance with conventional resist and etching operations, each as might be implemented in forming a single level mask.

An important aspect of the selected embodiments described herein is the ability to etch the light-absorbing (amorphous silicon) layers 12, 14, and 16 in a manner which essentially stops upon reaching the intervening etch-stop (silicon oxide) layers 20 and 22. Likewise, the etch-stop layers 20 and 22 can be etched without undue attack on the underlying light-absorbing layers 12, 14, and 16.

The photomask 110 of FIGS. 1-3 relies exclusively upon selective etching of multiple layers of uniform thickness to provide exposure and absorption regulation. An alternative implementation, however, is to control exposure through control of the thickness and the material composition of one or more of the individual layers.

FIG. 4 illustrates an alternate embodiment of a photomask 210 having layers of different thicknesses and varying materials. Photomask 210 includes a layer 216 of a first light-absorbing material and layers 214 and 212 of a second light-absorbing material. Layer 212 is only half the thickness of layer 214, thus providing a different incremental level of absorption. By varying the thickness of the light-absorbing layers, the absorption, and hence the exposure, can be accurately provided for any relative values. With more layers and different thicknesses almost any practical distribution of optical absorption can be achieved. The required thickness of the different layers can be readily calculated by use of well known optical formulae. For example, for a photomask having features as small as 0.25nm and for exposure using 365nm wavelength radiation, a typical deposition thickness for the light-absorbing layers 212, 214, and 216 will range between 100-800A, depending on the absorption characteristics of the layer. At a thickness of 100-800A, the light-absorption characteristics of an amorphous silicon layer range from I/I.sub.0 =0.5 to I/I.sub.0 =0.004. For this example, typical silicon oxide layers 20 and 22 will range from 100-500A, and offer a negligible light-absorbing range.

The present embodiment offers a photomask that contains regions which have varying levels of absorption and that, therefore, can produce an image that has received varying degrees of controlled exposure in different regions with a single exposure. Furthermore, by varying the number and the thickness of the layers 212, 214, and 216, the number of different levels of exposure that can be achieved simultaneously is practically limitless.

Once the photomask 210 has been patterned and inspected, the imprinted pattern can be aligned or registered on a wafer of a semiconductor device. FIG. 5 shows a flow diagram 300 showing the use of a photomask in the fabrication of a semiconductor device. Step 310 includes first providing a photomask, such as photomask 210, manufactured in accordance with the present invention. A semiconductor wafer under fabrication is then provided in step 312.

A thin layer of a selected photoresist is applied in step 314 to the portion of the wafer wherein the photomask pattern is to be registered. Prior to this step, the wafer may be cleaned to remove contaminants and primed, such as with hexamethyldisilazane (HMDS), to increase photoresist adhesion. The photoresist is a light-sensitive material that changes its properties when exposed to light. Exemplary photoresists may include positively acting etch-resistant organic polymers that photosolubilize in the presence of the selected form of light, such as an M-Cresolformaldehyde polymer. The photoresist may be selected to respond to a specific wavelength of light, differing exposing surfaces, resolution, polymerization or photosolubilization characteristics (negative or positive type photoresist), exposure speed, adhesion, or any specific needs of the specific application. In an exemplary method, the photoresist is applied to the surface to be processed in a liquid state by a photoresist spinning process. The photoresist is spread over the surface and dries to a thin film.

The photomask is precisely aligned over the surface to be treated in step 316. During step 318, the photomask and the underlying resist through the photomask are exposed to the selected form of light, such as ultra-violet light in the present embodiment. The photomask pattern is transferred to the photoresist coating on the wafer surface by optical printing. Upon exposure to the selected light-source, the different light-absorbing layers of the photomask allow different levels of exposure and, accordingly, different levels of polymerization or photosolubilization of the photoresist. The time, intensity, and form of radiation selected for exposure can be calibrated taking into account the desired pattern and the selected photoresist and photomask materials.

Upon completion of the exposure step in step 320, the photoresist is developed, such as by applying a solvent (developer) that does not affect the underlying wafer, but which dissolves the unpolymerized portions of the photoresist. The semiconductor wafer can then be etched, in step 322, using the remaining portions of the photoresist as an etch-resist mask. In step 324, the remaining photoresist is removed by processes known in the art, such as by an acetone soak.

While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.