U.S. patent application number 10/775695 was filed with the patent office on 2004-08-26 for resist polymer and method for producing the polymer.
Invention is credited to Kato, Ichiro, Mizuno, Kazuhiko, Oikawa, Tomo, Yamagishi, Takanori, Yamaguchi, Satoshi.
Application Number | 20040167298 10/775695 |
Document ID | / |
Family ID | 32866439 |
Filed Date | 2004-08-26 |
United States Patent
Application |
20040167298 |
Kind Code |
A1 |
Yamagishi, Takanori ; et
al. |
August 26, 2004 |
Resist polymer and method for producing the polymer
Abstract
Solving problems in the prior art, provided are a resist polymer
which is small in lot-to-lot, reactor-to-reactor and scale-to-scale
variations, and contains no high polymer, is excellent in
solubility and storage stability, and is suitable for fine pattern
formation, and a method for production thereof. The present
invention provides the resist polymer at least having a repeating
unit having a structure which is decomposed by an acid to become
soluble in an alkali developer and a repeating unit having a polar
group to enhance adhesion to a substrate, characterized in that a
peak area of a high molecular weight component (high polymer) with
molecular weight of 100,000 or more is 0.1% or less based on an
entire peak area in a molecular weight distribution determined by
gel permeation chromatography (GPC).
Inventors: |
Yamagishi, Takanori;
(Funabashi-shi, JP) ; Oikawa, Tomo; (Ichihara-shi,
JP) ; Kato, Ichiro; (Chiba-shi, JP) ; Mizuno,
Kazuhiko; (Sodegaura-shi, JP) ; Yamaguchi,
Satoshi; (Ichihara-shi, JP) |
Correspondence
Address: |
MELVIN I. STOLTZ, ESQ.
51 CHERRY STREET
MILFORD
CT
06460
US
|
Family ID: |
32866439 |
Appl. No.: |
10/775695 |
Filed: |
February 10, 2004 |
Current U.S.
Class: |
526/72 ;
526/319 |
Current CPC
Class: |
G03F 7/0397 20130101;
G03F 7/085 20130101 |
Class at
Publication: |
526/072 ;
526/319 |
International
Class: |
C08F 002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 20, 2003 |
JP |
042536/2003 |
Claims
What is claimed is:
1. A resist polymer at least having a repeating unit having a
structure which is decomposed by an acid to become soluble in an
alkali developer and a repeating unit having a polar group to
enhance adhesion to a substrate, characterized in that a peak area
of a high molecular weight component (high polymer) with molecular
weight of 100,000 or more is 0.1% or less based on an entire peak
area in a molecular weight distribution determined by gel
permeation chromatography (GPC).
2. The resist polymer according to claim 1, wherein said polymer is
produced by radical copolymerization with retaining a solution
containing polymerizable monomers and a solution containing a
polymerization initiator in respectively independent storage tanks
and supplying into a polymerization system continuously or
intermittently.
3. A method for producing a resist polymer at least having a
repeating unit having a structure which is decomposed by an acid to
become soluble in an alkali developer and a repeat unit having a
polar group to enhance adhesion to a substrate, characterized in
that radical co-polymerization is performed by retaining a solution
containing polymerizable monomers and a solution containing a
polymerization initiator in independent storage tanks respectively
and supplying them into a polymerization system continuously or
intermittently.
4. The method for producing the resist polymer according to claim
3, wherein the solution containing the polymerizable monomers is
previously heated before being supplied to polymerization
system.
5. The method for producing the resist polymer according to claims
3 or 4, wherein supplying the solution containing the
polymerization initiator to polymerization system is started prior
to supplying the solution containing the polymerizable
monomers.
6. The method for producing the resist polymer according to any of
claims 3-5, wherein the solution containing the polymerizable
monomers and the solution containing the polymerization initiator
are mixed in a polymerization tank by continuously or
intermittently supplying from the respectively independent storage
tanks into a polymerization solvent heated to polymerization
temperature.
7. The method for producing resist polymer according to any of
claims 3-6, wherein the solution containing the polymerizable
monomers and the solution containing the polymerization initiator
are previously mixed just before the polymerization and then
continuously or intermittently supplied into the polymerization
solvent heated to the polymerization temperature.
8. The method for producing the resist polymer according to any of
claims 3-7, wherein supplying rate of either or both of the
solution containing the polymerizable monomers and the solution
containing the polymerization initiator to polymerization system,
is changed by 2 or more steps.
9. The method for producing the resist polymer according to any of
claims 3-8, wherein the polymerization is conducted at or above a
temperature of the boiling point of polymerization solvent.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a resist polymer used for
the production of semiconductors and a method for the production
thereof. More particularly, the present invention relates to the
resist polymer, which is suitable for microfabrication using
various radiations such as far ultraviolet ray, X-ray and electron
beam, and excellent in storage stability, and the method for
production thereof.
[0003] 2. Description of Related Art
[0004] In semiconductor lithography, the formation of finer
patterns has been required in conjunction with increase of
integration degree. It is essential for micropatterning techniques
to make a wavelength of light source shorter. Currently, the
lithography by krypton fluoride (KrF) excimer laser (wavelength 248
nm) has become a mainstream, and the micropatterning technique of
100 nm linewidth or less by argon fluoride (ArF) excimer laser
(wavelength 193 nm) is coming into practical use. The
micropatterning techniques using fluorine dimer (F.sub.2) excimer
laser (wavelength 157 nm), extreme-ultraviolet ray (EUV), X-ray,
electron beam, and the like are in developmental stages.
[0005] The resist polymer used for these lithography technologies
has essentially a repeating unit having a non-polar substitute
which is decomposed by an acid and becomes soluble in an alkali
developer and a repeating unit having a polar group to enhance
adhesion to a semiconductor substrate. And if it is necessary, the
resist polymer is comprising a repeating unit having non-polar
substitutes to regulate solubility in a resist solvent or the
alkali developer. As these repeating units, for example, in the KrF
lithography, hydroxystyrenes and derivatives thereof have been
primarily used, and in the ArF lithography, (meth)acrylates and
derivatives thereof and the like have been considered because the
hydroxystyrenes absorb the light with a wavelength of 193 nm.
[0006] As specific examples of such resist polymers, copolymers of
(meth) acrylic monomer with styrene type monomer (see e.g., Patent
References 1 to 4), polymers containing hydroxystyrene which is
partially protected with acetal (see e.g., Patent References 5 to
8) and the like are known in the KrF lithography, and copolymers of
(meth) acrylic monomer having lactone structure (see e.g., Patent
references 9 to 10) are known in the ArF lithography.
[0007] Meanwhile, as the resist pattern becomes finer, high quality
of the resist polymer is strictly required. In particular, the
method for stable production of the resist polymer which is small
in lot-to-lot, reactor-to-reactor and scale-to-scale variations is
strongly required. As the commonest method for producing the resist
polymer, a so-called batch polymerization method has been known in
which basic ingredient monomers, a polymerization initiator and if
necessary a chain transfer agent are dissolved in a polymerization
solvent and polymerized with heat. However, in the batch
polymerization method, it is difficult to control a
temperature-rising rate constantly at all times. Therefore, there
has been a drawback that difference in amount of generated radical
species occurs at a stage of temperature-rising due to subtle
variations in the temperature-rising rate and causes lot-to-lot
variations in molecular weight distribution. Also, it has been
necessary to consider and change a heating condition in order to
reproduce the same temperature-rising rate regardless of shape and
scale of the reactor. In addition, in the case of batch
polymerization method, even if the same temperature-rising rate is
reproduced, there has been a drawback that difference of a radical
concentration occurs in the temperature-rising process due to
batch-to-batch variations in amount of dissolved oxygen, because a
trace quantity of radical generated by partial decomposition of the
polymerization initiator in the temperature-rising process is
trapped by dissolved oxygen in the polymerization solvent. And thus
difference easily occurs in weight average molecular weight and
molecular weight distribution. Additionally, since there is a
period of a low radical concentration and a high monomer
concentration in the temperature-rising process in the batch
polymerization method, there has been a problem that a trace amount
of a high molecular weight component (high polymer) with molecular
weight of 100,000 or more generates.
[0008] As the polymerization method which is not subject to the
temperature-rising rate, the method in which monomers and a chain
transfer agent as necessary are dissolved in the polymerization
solvent and heated to the polymerization temperature followed by
adding a polymerization initiator at a time or in some portions
(see e.g., Patent Reference 11) and the method in which the
polymerization initiator is added by dropwise over the definite
time (see e.g., Patent Reference 12) are known. However, there has
been a problem that a trace amount of high polymer generates
because the monomer is heated to the polymerization temperature in
the absence of the polymerization initiator in these methods.
[0009] Also, the method, so-called dropping polymerization method
is known, in which the polymerization is carried out by dropping a
solution containing monomers, a polymerization initiator and if
necessary a chain transfer reagent in the same solvent as the
polymerization solvent or different, into the polymerization
solvent heated up to the polymerization temperature (see e.g.,
Patent References 13 to 15). However, there has been a problem that
a trace amount of high polymer generates because the monomer is
retained in the coexistence with a polymerization initiator during
the period of the dropwise addition in this method.
[0010] As the method for suppressing the generation of high polymer
in a mixed solution of a monomer and a polymerization initiator,
the method in which a polymerization inhibitor is added is
considered. However, when a large amount of polymerization
inhibitor is added to suppress the generation of high polymer, it
likely affects the polymerization reaction. In addition, in the ArF
lithography, there has been a problem that a phenol type compound
such as 4-methoxyphenol generally used as the polymerization
inhibitor is left in the polymer and absorbs the light with a
wavelength of 193 nm. Besides, according to the study by the
present inventors, radical species can be consumed by dissolved
oxygen and the generation of high polymer can be suppressed to some
extent, by retaining the mixed solution of the monomer and the
polymerization initiator under an air atmosphere instead of adding
the polymerization inhibitor. But there is a possibility of
explosion and fire disaster in this method, which could not be
industrially practiced in terms of safety.
[0011] When the above high polymer generates, solubility of the
obtained resist polymer to a resist solution and an alkali
developer becomes poor. Even if the high polymer is dissolved
initially, it nucleates and sometimes makes an insoluble foreign
substance grow and precipitate in storage with time. It is highly
possible that these insoluble matters become a cause of defects of
the resist pattern. Thus, it has been strongly desired to provide a
resist polymer which does not contain the high polymer and a method
for the production thereof.
[0012] Patent Reference 1
[0013] JP-A-59-45439
[0014] Patent Reference 2
[0015] JP-A-5-113667
[0016] Patent Reference 3
[0017] JP-A-7-209868
[0018] Patent Reference 4
[0019] JP-A-11-65120
[0020] Patent Reference 5
[0021] JP-A-62-115440
[0022] Patent Reference 6
[0023] JP-A-4-219757
[0024] Patent Reference 7
[0025] JP-A-3-223860
[0026] Patent Reference 8
[0027] JP-A-4-104251
[0028] Patent Reference 9
[0029] JP-A-9-73173
[0030] Patent Reference 10
[0031] JP-A-10-239846
[0032] Patent Reference 11
[0033] JP-A-2001-109153
[0034] Patent Reference 12
[0035] JP-A-2002-6501 (Examples)
[0036] Patent Reference 13
[0037] JP-A-4-269754 (Examples)
[0038] Patent Reference 14
[0039] JP-A-11-295894
[0040] Patent Reference 15
[0041] International Publication WO99/50322
SUMMARY OF THE INVENTION
[0042] The present invention has been completed against the above
background, and the objective thereof is to provide a resist
polymer which is small in lot-to-lot, reactor-to-reactor, and
scale-to-scale variations, and does not contain a high polymer, is
excellent in solubility and storage stability, and is suitable for
fine pattern formation in the semiconductor lithography, and a
method for the production thereof.
[0043] As a result of an intensive study for solving the above
problems, the present inventors have found that a monomer can be
introduced into a system without being subject to a
temperature-rising rate and concurrently it is possible to suppress
the generation of a high polymer by introducing a basic ingredient
monomer and a polymerization initiator by a particular method in
the drop polymerization method, and resist polymer which is
excellent in solubility and storage stability is obtained, and have
completed the invention.
[0044] That is, the present invention provides the resist polymer
at least having a repeating unit having a structure which is
decomposed by an acid to become soluble in an alkali developer and
a repeating unit having a polar group to enhance adhesion to a
substrate, characterized in that a peak area of a high molecular
weight component (high polymer) with a molecular weight of 100,000
or more is 0.1% or less based on an entire peak area in a molecular
weight distribution determined by gel permeation chromatography
(GPC).
[0045] Also, the present invention provides a method for producing
a resist polymer at least having a repeating unit having a
structure which is decomposed by an acid to become soluble in an
alkali developer and a repeating unit having a polar group to
enhance adhesion to a substrate, characterized in that radical
copolymerization is performed by retaining a solution containing
polymerizable monomers and a solution containing a polymerization
initiator in independent storage tanks respectively and supplying
them into a polymerization system continuously or
intermittently.
[0046] Also, present invention provides a method for producing the
resist polymer, wherein the solution containing the polymerizable
monomers is previously heated before being supplied to
polymerization system.
[0047] Also, the present invention provides a method for producing
the resist polymer, wherein supplying the solution containing the
polymerization initiator to polymerization system is started prior
to supplying the solution containing the polymerizable
monomers.
[0048] Further, the present invention provides a method for
producing the resist polymer, wherein the solution containing the
polymerizable monomers and the solution containing the
polymerization initiator are mixed in a polymerization tank by
continuously or intermittently supplying from the respectively
independent storage tanks into a polymerization solvent heated to
polymerization temperature.
[0049] Further, the present invention provides a method for
producing resist polymer, wherein the solution containing the
polymerizable monomers and the solution containing the
polymerization initiator are previously mixed just before the
polymerization and then continuously or intermittently supplied
into the polymerization solvent heated to the polymerization
temperature.
[0050] Furthermore, the present invention provides a method for
producing the resist polymer, wherein supplying rate of either or
both of the solution containing the polymerizable monomers and the
solution containing the polymerization initiator to polymerization
system, is changed by 2 or more steps.
[0051] Furthermore, the present invention provides a method for
producing the resist polymer, wherein the polymerization is
conducted at or above temperature of the boiling point of
polymerization solvent.
DETAILED DESCRIPTION OF THE INVENTION
[0052] The present invention is described in detail below.
[0053] The monomers as the raw material used for the present
invention is not limited particularly as long as they are monomers
having polymerizable ethylenic double bond in its structure. The
resulting resist polymer is comprising at least a repeating unit
having a structure which is decomposed by an acid to become soluble
in an alkali developer, more specifically, the repeating unit (A)
having the structure where a non-polar substituent is eliminated by
the acid and a polar group soluble in the alkali developer emerges,
and a repeating unit (B) having a polar group to enhance adhesion
to a substrate. And if it is necessary, the resist polymer is
comprising a repeating unit (C) having a non-polar and acid-stable
substituent to regulate the solubility in a resist solvent or the
alkali developer.
[0054] The structure which is decomposed by the acid to become
alkali-soluble in the repeating unit (A) means a conventional
structure for resist polymer, and can be obtained by
co-polymerization of the monomer having the structure which is
decomposed by the acid and becomes alkali-soluble, or by
co-polymerization of the monomer having an alkali-soluble polar
structure (alkali-soluble group) and followed by protection of the
alkali-soluble group by an acid-labil non-polar structure
(acid-labil protecting group).
[0055] The monomers having the structure which is decomposed by the
acid to become alkali-soluble can include compounds having
alkali-soluble groups protected by acid-labil protecting groups,
and for example, can include compounds having phenolic hydroxyl
group, carboxyl group or hydroxylfluoroalkyl group protected by the
acid-labil protecting groups.
[0056] Therefore, the polymerizable compounds having the
alkali-soluble groups can include, specifically for example,
hydroxystyrenes such as p-hydroxystyrene, m-hydroxystyrene and
p-hydroxy-.alpha.-methylstyrene; carboxylic acids having
ethylenical double bonds such as acrylic acid, methacrylic acid,
trifluoromethylacrylic acid, 5-norbornene-2-carboxylic acid,
2-trifluoromethyl-5-norbornene-2-carboxylic acid and
carboxytetracyclo [4.4.0.1.sup.2,5.1.sup.7,10] dodecyl
methacrylate; polymerizable compounds having hydroxyfluoroalkyl
groups such as p-(2-hydroxy-1,1,1,3,3,3-hexafluoro-2-propyl)
styrene, 2-(4-(2-hydroxy-1,1,1,3,3,3-hexafluoro-2-propyl)
cyclohexyl)-1,1,1,3,3,3-- hexafluoropropyl acrylate,
2-(4-(2-hydroxy-1,1,1,3,3,3-hexafluoro-2-propyl- )
cyclohexyl)-1,1,1,3,3,3-hexafluoropropyl trifluoromethylacrylate
and 5-(2-hydroxy-1,1,1,3,3,3-hexafluoro-2-propyl)
methyl-2-norbornene, and the like.
[0057] The acid-labil protecting groups can include saturated
hydrocarbon groups such as tert-butyl group, tertamyl group,
1-methyl-1-cyclopentyl group, 1-ethyl-1-cyclopentyl group,
1-methyl-1-cyclohexyl group, 1-ethyl-1-cyclohexyl group,
2-methyl-2-adamantyl group, 2-ethyl-2-adamantyl group,
2-propyl-2-adamantyl group, 2-(1-adamantyl)-2-propyl group,
8-methyl-8-tricyclo [5.2.1.0.sup.2,6.] decanyl group,
8-ethyl-8-tricyclo [5.2.1.0.sup.2,6.] decanyl group,
8-methyl-tetracyclo [4.4.0.1.sup.2,5.1.sup.7,10] dodecanyl group
and 8-ethyl-tetracyclo [4.4.0.1.sup.2,5.1.sup.7,10] dodecanyl
group; oxygen-containing hydrocarbon groups such as 1-methoxyethyl
group, 1-ethoxyethyl group, 1-isopropoxyethyl group,
1-n-butoxyethyl group, 1-tert-butoxyethyl group,
1-cyclopentyloxyethyl group, 1-cyclohexyloxyethyl group, 1-tricyclo
[5.2.1.0.sup.2,6] decanyloxyethyl group, methoxymethyl group,
ethoxymethyl group, isopropoxymethyl group, n-butoxymethyl group,
tert-butoxymethyl group, cyclopentyloxymethyl group,
cyclohexyloxymethyl group, tricyclo [5.2.1.0.sup.2,6]
decanyloxymethyl group and tert-butoxycarbonyl group; and the
like.
[0058] In the case of the co-polymerization of the monomer having
the alkali-soluble and followed by protection of the alkali-soluble
group by the acid-labil group, the above compound having the
alkali-soluble group can be used for the co-polymerization and the
alkali-soluble group can be substituted to the acid-labil
protecting group by subsequent reaction under an acid catalyst with
the compound capable to give the substituent such as vinyl ethers
and haloalkyl ethers which is not dissolved in alkali. The acid
catalysts used for the reaction can include p-toluenesulfonic acid,
trifluoroacetic acid, strongly acidic cation exchange resin and the
like.
[0059] At the same time, the monomers which give the repeat unit
(B) having the polar group to enhance the adhesion to the substrate
can include the compounds having phenolic hydroxyl group, carboxyl
group, hydroxyfluoroalkyl group and the like as the polar groups.
Specifically the monomers can include, for example, hydroxystyrenes
and carboxylic acids having an ethylenic double bond and
polymerizable compounds having hydroxyfluoroalkyl group described
above as the polymerizable compounds having the alkali-soluble
group, and monomers where polar groups are further substituted
thereto, and additionally monomers where polar groups are bound to
an alicyclic structure such as norbornene ring and
tetracyclododecene ring.
[0060] As the above polar group introduced in the repeat unit (B),
particularly preferable are the substituents comprising a lactone
structure, and for example, it is possible to include substituents
comprising the lactone structure such as .gamma.-butyrolactone,
7-valerolactone, .delta.-valerolactone,
1,3-cyclohexanecarbolactone, 2,6-norbornanecarbolactone,
4-oxatricyclo [5.2.1.0.sup.2,6] decane-3-one and mevalonic acid
.delta.-lactone. Besides, the polar groups other than the lactone
structure can include hydroxyalkyl groups such as hydroxymethyl
group, hydroxyethyl group, hydroxypropyl group and
3-hydroxy-1-adamantyl group, and the like.
[0061] Further the monomers contained as necessary which give the
repeating unit (C) having acid-stable non-polar substituents to
regulate solubility in the resist solvent or the alkali developer
can include, for example, compounds having substituted or
unsubstituted alkyl or aryl groups containing no polar group, and
compounds having polar groups protected with non-polar and
acid-stable groups, and specifically can include, for example,
styrenes such as styrene, .alpha.-methylstyrene and
p-methylstyrene; ester compounds where acid-stable non-polar groups
are substituted to carboxylic acid having an ethylenic double bond
such as acrylic acid, methacrylic acid, trifluoromethylacrylic
acid, norbornenecarboxylic acid,
2-trifluoromethylnorbornenecarboxylic acid and carboxytetracyclo
[4.4.0.1.sup.2,5.1.sup.7,10] dodecyl methacrylate; alicyclic
hydrocarbon compounds having an ethylenic double bond such as
norbornene and tetracyclododecene, and the like. Examples of
acid-stable non-polar substituents, which are substituted to the
above carboxylic acid and give ester compounds, can include methyl
group, ethyl group, cyclopentyl group, cyclohexyl group, isobornyl
group, tricyclo [5.2.1.0.sup.2,6] decanyl group, 2-adamantyl group,
tetracyclo [4.4.0.1.sup.2,5. 1.sup.7,1] dodecyl group and the
like.
[0062] These monomers can be used in mixture with one or two or
more types for the respective repeating units (A), (B) and (C), and
a composition ratio of the respective repeating units in the
obtained resist polymer can be selected within the range in which
the performance of resist is not impaired. The composition ratio of
the repeating unit (A) is preferably from 10 to 70 mol %, and more
preferably from 10 to 60 mol %. And, the composition ratio of the
repeating unit (B) is preferably from 30 to 90 mol %, and more
preferably from 40 to 90 mol %, but if some monomer units have same
polar group, it is preferably 70 mol % or less. Moreover, the
composition ratio of the repeating unit (C) is preferably from 0 to
50 mol %, and more preferably from 0 to 40 mol %.
[0063] Also, the weight-average molecular weight (Mw) of the resist
polymer is preferably in the range of 2,000 to 40,000, more
preferably from 3,000 to 30,000, and especially preferably from
4,000 to 25,000. When it is excessively high, the solubility of the
resist polymer into the resist solvent or the alkali developer
becomes low. When it is excessively low, coating film performance
becomes poor.
[0064] The polymerization initiator used in the polymerization
includes, but is not limited to, for example, azo compounds such as
2,2'-azobisisobutyronitrile, 2,2'-azobis (2-methylbutyronitrile),
dimethyl 2,2'-azobis(isobutylate), 1,1'-azobis
(cyclohexane-1-carbonitril- e) and 4,4'-azobis (4-cyanovaleric
acid), and organic peroxide compounds such as didecanoyl peroxide,
dilauroyl peroxide, dibenzoyl peroxide, bis
(3,5,5-trimethylhexanoyl) peroxide, succinic acid peroxide and
tert-butyl peroxy-2-ethylhexanoate. The polymerization initiator
may be used either individually or in combination of two or more.
The amount of the polymerization initiator can be selected from a
broad range depending on types and amounts of the monomers and the
chain transfer agent, and polymerization conditions like
polymerization temperature and polymerization solvents.
[0065] A chain transfer agent may be used in the polymerization,
and it is possible to use, for example, thiol compounds such as
dodecanethiol, mercaptoethanol, mercaptopropanol, mercaptoacetic
acid and mercaptopropionic acid alone or in mixture. The chain
transfer agent may be used by dissolving with the monomer in the
monomer solution, or may be used by dissolving with the
polymerization initiator in the polymerization initiator
solution.
[0066] Solvents used for the polymerization reaction include the
solvent used for the solution containing the monomers, the solvent
used for solution containing the polymerization initiator and the
solvent put in a reaction container. These are not particularly
limited as long as they are the solvents which allow the monomers,
the polymerization initiator and the resultant polymer to be
dissolved, and may be the same or different from one another.
Specific examples can include ketones such as acetone, methyl ethyl
ketone and methyl amyl ketone, ethers such as tetrahydrofuran,
dioxane, glyme, propylene glycol monomethyl ether, esters such as
ethyl acetate and ethyl lactate, etheresters such as propylene
glycol methyl ether acetate, lactones such as
.gamma.-butyrolactone, and the like, and these can be used alone or
in mixture.
[0067] The resist polymer of the present invention comprises at
least having a repeating unit having a structure which is
decomposed by an acid to become soluble in an alkali developer and
a repeating unit having a polar group for enhancing adhesion to a
substrate, characterized in that a peak area of a high molecular
weight component (high polymer) with molecular weight of 100,000 or
more is 0.1% or less based on an entire peak area in a molecular
weight distribution determined by gel permeation chromatography
(GPC). In the resist polymer of the present invention, it is
possible to suppress the generation of high polymer which is the
high molecular weight component with a molecular weight of 100,000
or more and make the content of high polymer being 0.1% or less, by
retaining the solution containing the basic ingredient monomer
(hereinafter abbreviated as monomer solution in some cases) and the
solution containing the polymerization initiator (hereinafter
abbreviated as initiator solution in some cases) both described
above in respective independent storage tanks and supplying into
the polymerization system continuously or intermittently to perform
the radical copolymerization. Here, the content of high polymer can
be given as a ratio of a peak area of the high polymer based on an
entire peak area in the molecular weight distribution determined by
GPC. In the present invention, the molecular weight distribution by
GPC was calculated using a refractive index detector (RI) based on
a standard curve made by commercially available polystyrene
standard samples.
[0068] It is more preferable that a concentration of the monomer in
the monomer solution and a concentration of the polymerization
initiator in the initiator solution which are supplied to the
reaction system are high in terms of productivity. Especially, when
the monomer and the polymerization initiator are in the form of
liquid, it is possible to supply them neat without dissolving into
solvent. But when the monomer and the polymerization initiator are
in the form of viscous liquid or solid, they should be used after
dissolving into solvent. In case where the monomer and the
polymerization initiator are used with solvent, if the
concentration is excessively high, viscosity of the solutions
sometimes becomes high to worsen operationality and the solid
monomer or the polymerization initiator sometimes precipitate.
Therefore, it is preferable to select the concentrations at which
the monomer and the polymerization initiator are thoroughly
dissolved and do not precipitate during the dropwise addition in a
viscosity range which does not worsen operationality. The specific
concentrations vary depending on the combination of a solute and a
solvent in each solution, but typically they are prepared such that
the sum concentration of total monomers and the concentration of
the polymerization initiator are in the range of, for example from
5 to 60% and preferably from 10 to 50% by mass, respectively.
[0069] Preparation of the monomer solution and the initiator
solution having higher concentration is possible by previously
heating the solutions before supplying them to polymerization
system, since the solubility of the monomer solution and the
initiator solution is improved. However, the initiator solution
should be in a temperature range of generally, for example,
50.degree. C. or below, preferably, 40.degree. C. or below, because
the polymerization initiator may be decomposed in a high
temperature range. On the other hand, the monomer solution should
preferably be supplied after being previously heated in a storage
tank or just before supplying them to polymerization system by a
heat exchanger. This is because when the temperature of the monomer
solution is too low, supplied monomer solution in the heated
polymerization system is kept at low temperature locally, and the
generation of high polymer may occur. Accordingly, the monomer
solution may be previously heated in a temperature range of, for
example, 25.degree. C. or higher, preferably, 40.degree. C. or
higher. It should be noted that when the monomer solution is
previously heated in a storage tank, the monomer solution is kept
heated for a long term, and the generation of high polymer may
occur under high temperature. Accordingly, it is preferred that
previous heating may be conducted in a temperature range of, for
example, 50.degree. C. or below. When the monomer solution is
previously heated just before supplying the same to polymerization
system by the heat exchanger, the storage term under high
temperature is short, and accordingly, it is possible to heat the
monomer solution to higher temperature, e.g., polymerization
temperature.
[0070] In the present invention, since the monomer solution and the
initiator solution are supplied into the polymerization system,
i.e., a polymerization solvent previously heated to the
polymerization temperature, they are less subject to the
temperature-rising rate comparably to the conventional drop
polymerization method. Therefore the stable resist polymer is
obtained which is small in lot-to-lot, reactor-to-reactor, and
scale-to-scale variations. Especially, when the polymerizable
monomer solution is previously heated and supplied, temperature
deviation in the reaction system is suppressed more efficiently,
and the resist polymer having more stable properties is
obtained.
[0071] An amount of the polymerization solvent put in the reaction
container could be a minimum amount or more capable of being
stirred. When the initial putting amount is more than needs, it is
not preferable because the amount of the monomer solution which can
be supplied becomes small and the production efficiency is reduced.
Typically, the amount is selected from a volume ratio of 1/20 or
more and preferably from the range of about 1/10 to 1/2 based on a
final feeding amount (i.e., the sum amount of the initial feeding
amount, the monomer solution and the initiator solution).
[0072] The polymerization temperature varies depending on boiling
points of the polymerization solvents used, a half life of the
polymerization initiator and the like. When it is higher than
necessary, there is a problem in stability of the monomer and the
resist polymer. Thus, the temperature is preferably selected from
the range of 60 to 120.degree. C. and more preferably from 70 to
100.degree. C. The polymerization temperature is controlled such
that the temperature in the system is not lowered by feeding the
monomer solution and the initiator solution, is preferably retained
within a setting temperature .+-.5.degree. C. and especially
preferably the setting temperature .+-.3.degree. C. Incidentally,
the local temperature deviation in the reaction system is
suppressed more efficiently by, as mentioned above, previously
heating the monomer solution before supplying. Also, the
temperature deviation in the reaction system may be suppressed by
setting the polymerization temperature to the boiling point of the
solvent or more, and conducting the reaction under reflux of the
solvent.
[0073] The monomer solution and the initiator solution may be
supplied from respective storage tanks independently to the
polymerization tank, or may be supplied by premixing just before
the polymerization. A supplying rate of the monomer solution and
the initiator solution can be independently set such that resist
polymer having the desired molecular weight distribution is
obtained. It is also possible to obtain the resist polymer which
has the various molecular weight distributions from narrow
dispersion to polydispersion with good reproducibility by altering
the supplying rate(s) of either or both of two solutions. For
example, when the supplying rate of the initiator solution at a
first half stage of the reaction is reduced, and the supplying rate
of the initiator solution at a second half stage is increased,
polymer having relatively low molecular weight is formed at a first
half stage (radical concentration is low), and the resist polymer
of polydispersion is obtained. The supplying rate(s) of either or
both of two solutions may be changed continuously or stepwise, but
the supplying rate(s) may preferably be change at least 2 steps or
more.
[0074] It is possible to keep the constitution and the temperature
of the monomer and the concentration of radical in the
polymerization system constant by supplying the two solution as
slowly as possible. This enables reducing changes in the
composition and the molecular weight of the resist polymer
generated at an initial phase and a terminal phase of the
polymerization. However, when the supplying rate is excessively
slow, it takes a long time to feed and the production efficiency
becomes poor. Also, deterioration of the monomer solution sometimes
becomes problematic for the monomer with low stability. Therefore,
the feeding time for each solution is selected from the range of
0.5 to 20 hours and preferably from 1 to 10 hours. An initiation
sequence is not especially limited, but it is preferred that the
two solutions are fed simultaneously or that the polymerization
initiator is fed in advance to avoid the formation of the high
polymer. That is, the polymerization initiator is preferably fed in
advance to the monomer solution, because certain time is required
for the polymerization initiator being decomposed in the
polymerization system and generating radicals.
[0075] The polymerization reaction is initiated along with the feed
of the monomer solution and the polymerization initiator solution
and continued, but it is preferred to react the residual unreacted
monomer by maturing with keeping the polymerization temperature for
a definite time after the completion of feed. A maturing time is
selected within 6 hours and preferably in the range of 1 to 4
hours. When the maturing time is excessively long, it is not
preferable because the production efficiency per time is reduced
and heating history more than needs is given to the polymer.
[0076] The resist polymer after the polymerization can be purified
by adding the polymer solution to a poor solvent, or a mixed
solvent of the poor solvent and a good solvent dropwise to
coagulate, and further washing with above solvent if necessary for
removing unwanted matters such as residual monomers, oligomers, the
polymerization initiator, the chain transfer agent and reaction
residues thereof. The poor solvent is not particularly limited as
long as it is the solvent in which the resultant copolymer is not
dissolved, and for example, it is possible to use water, alcohols
such as methanol and isopropanol, saturated hydrocarbons such as
hexane and heptane, and the like. The good solvent is not
particularly limited as long as it is the solvent in which the
monomers, the oligomers, the polymerization initiator, the chain
transfer agent and the reaction residues thereof are dissolved, but
it is preferred that the good solvent is the same as the
polymerization solvent in terms of management of production
steps.
[0077] The solvent used for purification is comprised in the resist
polymer after the purification. Thus, a resist solution is finished
by drying under reduced pressure followed by dissolving in a resist
solvent, or by distilling off the other solvent under reduced
pressure with supplying the resist solvent if necessary after
dissolving in the good solvent such as the resist solvent and the
polymerization solvent. The resist solvent is not particularly
limited as long as it dissolves the resist polymer, but typically
selected taking a boiling point, effects on the semiconductor
substrate and the other coating films and absorption of radiation
used for lithography into consideration. Examples of the resist
solvents generally used include the solvents such as propylene
glycol methyl ether acetate, ethyl lactate, methyl amyl ketone,
.gamma.-butyrolactone and cyclohexanone. The use amount of the
resist solvent is not particularly limited, and is typically in the
range of 1 to 20 parts by weight based on 1 part by weight of the
resist polymer.
[0078] A resist composition can be completed by blending in this
resist solution a photo acid generator and an acid diffusion
control agent such as a nitrogen-containing basic compound capable
of suppressing the rate of acid diffusion within parts which are
not exposed. As the photo acid generator, it is possible to use
those generally used as basic ingredients for the resist such as
onium salts, sulfone compounds, sulfonate esters, sulfonimide
compounds and disulfonyldiazomethane compounds. Also if necessary,
in the resist composition, it is possible to blend other compounds
commonly used as additives for the resist such as a dissolution
inhibitor, a sensitizer and dyes.
[0079] The combination ratio of respective ingredients (excluding
the resist solvent) in the resist composition is generally selected
from the ranges of 10 to 50% by mass for the polymer concentration,
from 0.1 to 10% by mass for the photo acid generator and from 0.001
to 10% by mass for the acid diffusion controlling agent (reminder
is solvent).
EXAMPLES
[0080] Next, the present invention is further described by
following examples, but the invention is not limited to these
examples.
[0081] In the examples, % which represents a concentration is on
the basis of mass unless otherwise defined except the content of
high polymer (%: area percent). Quantification of the high polymer
in the obtained resist polymer and evaluation of storage stability
were performed by the methods shown below.
[0082] (1) Quantification Method of High Polymer in Resist
Polymer
[0083] The high polymer in the resist polymer was quantified by
GPC. An analysis condition and the quantification condition are as
follows.
[0084] Apparatus: GPC 8020 supplied from Tosoh Corporation
[0085] Detector: Differential refractive index (RI) detector
[0086] Column: KF-804L (3) supplied from Showa Denko K.K.
[0087] Sample amount: The obtained polymer solution after the
polymerization was sampled and diluted with tetrahydrofuran to
prepare the polymer sample solution containing 1% polymer.
[0088] Quantification: To GPC, 15 .mu.l of the above sample was
applied, and a peak area, Ap of the target polymer was obtained.
Then 150 .mu.l of the above sample was applied and a peak area, Ah
of the high polymer was obtained. From these results, the content
(%) of high polymer in the polymer was calculated on the basis of
the following calculation formula.
[0089] Content of high polymer (%)
Ah/{(Ap.times.10)+Ah}.times.100
[0090] (2) Evaluation Method of Storage Stability of Resist
Polymer
[0091] The resist polymer, 15% propylene glycol methyl ether
acetate solution (hereinafter inscribed as "PGMEA") was prepared,
and particles were measured in the solution after storing at room
temperature for 3 months.
[0092] Apparatus: KS-40B supplied from Rion Co., Ltd.
[0093] Evaluation: The case where there were less than 10/ml of
foreign matters with particle size of 0.2 .mu.m or more was
rendered "AA", the case where there were from 10/ml or more to less
than 100/ml was rendered "A", the case where there were from 100/ml
or more to less than 1000/ml was rendered "B" and the case where
there were more than 1000/ml was rendered "C".
EXAMPLE 1
[0094] Production of Copolymer 1
[0095] A monomer solution was prepared by placing 4800 g of methyl
ethyl ketone (hereinafter inscribed as "MEK") in a tank kept at a
nitrogen atmosphere, and dissolving 2080 g of
5-acryloyloxy-2,6-norbornanecarbolac- tone (hereinafter inscribed
as "NLA") as a repeat unit (B) having a polar group for enhancing
adhesion to a semiconductor substrate {hereinafter (B) on a head of
the compounds in the examples has the same meaning as this} and
2480 g of 2-ethyl-2-adamantyl methacrylate (hereinafter inscribed
as "EAM") as a repeat unit (A) which is decomposed by an acid to
become alkali soluble (hereinafter (A) on a head in the compounds
in the examples has the same meaning as this). A polymerization
initiator was prepared by placing 700 g of MEK and 80 g of
azobisisobutyronitrile (hereinafter inscribed as "AIBN") in another
container kept at a nitrogen atmosphere and dissolving. Into a
polymerization tank kept at the nitrogen atmosphere, 3500 g of MEK
was put and the temperature was raised to 80.degree. C. with
stirring. Subsequently, the monomer solution and the polymerization
initiator solution kept at the temperature of 25 to 30.degree. C.
were fed into the polymerization tank kept at 80.degree. C. over 4
hours, respectively. After the completion of feed, the polymerized
solution was matured for 2 hours with keeping the polymerization
temperature at 80.degree. C., then cooled to room temperature and
taken out. Polymer was precipitated from the resulting polymerized
solution by dropping in 70 kg of aqueous methanol and filtrated.
The resultant wet cake was washed with 70 kg of methanol, filtrated
subsequently dissolved in MEK again, and passed through a filter
40QSH supplied from Cuno Incorporated to remove a trace amount of
metals. Then, the solvent was replaced by PGMEA with removing MEK
by heating under reduced pressure to prepare PGMEA solution
containing 15% polymer. The features of the resultant polymer, the
content of high polymer and the evaluation results of storage
stability of PGMEA solution are shown in Table 1.
EXAMPLE 2
[0096] Production of Copolymer 2 (1)
[0097] A monomer solution was prepared by placing 8000 g of MEK in
a tank kept at a nitrogen atmosphere and dissolving 2080 g of (B)
NLA, 2480 g of (A) EAM and 2220 g of 3-hydroxy-1-adamantyl acrylate
(hereinafter inscribed as "HAA"). Also, a polymerization initiator
was prepared by placing and dissolving 1000 g of MEK and 110 g of
AIBN in another container kept at the nitrogen atmosphere. Into a
polymerization tank kept at the nitrogen atmosphere, 5000 g of MEK
was put and the temperature was raised to 80.degree. C. with
stirring. Subsequently, the monomer solution and the polymerization
initiator solution kept at the temperature of 25 to 30.degree. C.
were fed into the polymerization tank kept at 80.degree. C. over 4
hours, respectively. After the completion of feed, the polymerized
solution was matured for 2 hours with keeping the polymerization
temperature at 80.degree. C., then cooled to room temperature and
taken out. Polymer was precipitated from the resulting polymerized
solution by dropping in 100 kg of aqueous methanol and filtrated.
The resultant wet cake was washed with 100 kg of methanol,
filtrated subsequently dissolved in MEK again, and passed through a
filter 40QSH supplied from Cuno Incorporated to remove a trace
amount of metals. Then, the solvent was replaced by PGMEA with
removing MEK by heating under reduced pressure to prepare PGMEA
solution containing 15% polymer. The features of the resultant
polymer, the content of high polymer and the evaluation results of
storage stability of PGMEA solution are shown in Table 1.
EXAMPLE 3
[0098] Production of Copolymer 3 (1)
[0099] A monomer solution was prepared by placing 7000 g of MEK in
a tank kept at a nitrogen atmosphere and dissolving 2220 g of (B)
5-methacryloyloxy-2,6-norbornanecarbolactone (hereinafter inscribed
as "NLM"), 2480 g of EAM and 90 g of methacrylic acid. Also, a
polymerization initiator was prepared by placing and dissolving 700
g of MEK and 80 g of AIBN in another container kept at the nitrogen
atmosphere. Into a polymerization tank kept at the nitrogen
atmosphere, 3300 g of MEK was put and the temperature was raised to
80.degree. C. with stirring. Subsequently, the monomer solution and
the polymerization initiator solution kept at the temperature of 25
to 30.degree. C. were fed into the polymerization tank kept at
80.degree. C. over 4 hours, respectively. After the completion of
feed, the polymerized solution was matured for 2 hours with keeping
the polymerization temperature at 80.degree. C., then cooled to
room temperature and taken out. Polymer was precipitated from the
resulting polymerized solution by dropping in 80 kg of aqueous
methanol and filtrated. The resultant wet cake was washed with 80
kg of methanol, filtrated subsequently dissolved in MEK again, and
passed through a filter 40QSH supplied from Cuno Incorporated to
remove a trace amount of metals. Then, the solvent was replaced by
PGMEA with removing MEK by heating under reduced pressure to
prepare PGMEA solution containing 15% polymer. The features of the
resultant polymer, the content of high polymer and the evaluation
results of storage stability of PGMEA solution are shown in Table
1.
EXAMPLE 4
[0100] Production of Copolymer 2 (2)
[0101] Examples 4 is conducted by polymerizing purifying and
preparing the PGMEA solution by the same procedure as that in the
example 2, except that the monomer solution is heated just before
supplying it to the reaction system by a heat exchanger to
40.degree. C. The features of the resultant polymer, the content of
high polymer and the evaluation results of storage stability of
PGMEA solution are shown in Table 1.
EXAMPLE 5
[0102] Production of Copolymer 3 (2)
[0103] Examples 5 is conducted by polymerizing purifying and
preparing the PGMEA solution by the same procedure as that in the
example 3, except that the polymerization initiator solution is
prepared by changing fed amount of AIBN to 140 g, and; changing fed
amount of MEK to 1030 g; and changing supplying rate of the
polymerization initiator solution to 0.6 g/min for the first 1 hour
and to 6.3 g/min for consequent 3 hours. The features of the
resultant polymer, the content of high polymer and the evaluation
results of storage stability of PGMEA solution are shown in Table
1.
EXAMPLE 6
[0104] Production of Copolymer 2 (3)
[0105] Examples 6 is conducted by polymerizing purifying and
preparing the PGMEA solution by the same procedure as that in the
example 2, except that supplying period of the polymerization
initiator solution is changed to 4.5 hours, and supplying the
monomer solution is initiated after 0.5 hours interval of supplying
the polymerization initiator solution. The features of the
resultant polymer, the content of high polymer and the evaluation
results of storage stability of PGMEA solution are shown in Table
1.
COMPARATIVE EXAMPLES 1 to 3
[0106] Comparative examples 1 to 3 were made by polymerizing and
preparing the PGMEA solution by the same procedure as that in the
examples 1 to 3, except that the monomer solution and the
polymerization initiator were kept in a sigle tank and fed in
mixture from the tank. The features of the resultant polymer, the
content of high polymer and the evaluation results of storage
stability of PGMEA solution are shown in Table 1.
1 TABLE 1 High polymer Composition (mol %) GPC Content Storage NLA
NLM EAM HAA MA Mw Mw/Mn (area %) Mw stability Example 1 49 -- 51 --
-- 8,400 2.04 ND -- A Example 2 34 -- 33 33 -- 10,300 1.97 ND -- A
Example 3 -- 59 36 -- 5 8,000 1.61 ND -- A Example 4 34 -- 33 33 --
10,200 1.95 ND -- AA Example 5 -- 59 36 -- 5 8,000 2.03 ND -- A
Example 6 34 -- 33 33 -- 9,700 1.81 ND -- AA Comparative 50 -- 50
-- -- 8,400 2.05 0.33 249,000 C example 1 Comparative 33 -- 33 34
-- 10,400 1.95 0.58 281,000 C example 2 Comparative -- 59 36 -- 5
7,900 1.63 0.26 257,000 C example 3
[0107] As is obvious from these results, the high polymer generated
in the conventional method in which the monomer and the
polymerization initiator were supplied in mixture, and growth of
insoluble foreign substances was observed during the storage
period. Meanwhile, in the present invention, it is found that no
high polymer generates and the resist polymer which is excellent in
storage stability is obtained by feeding the polymerizable monomer
and the polymerization initiator each independently.
[0108] Advantage of the Invention
[0109] According to the present invention, since the method is less
subject to the temperature-rising rate comparably to the
conventional dropping polymerization method, it is possible to
obtain the resist polymer which is small in lot-to-lot,
reactor-to-reactor and scale-to-scale variations. Concurrently,
since no high polymer is included, it is possible to provide resist
polymer which is excellent in solubility, in which no growth of
insoluble foreign substances is observed in the storage with time,
and which is suitable for the formation of stable and fine resist
pattern.
* * * * *