Oblong Aperture Arrays for Multi-Beam Lithography Cut Patterns
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Solution Overview
Problem
Current multi-beam lithography tools face challenges in efficiently writing one-dimensional circuit designs with high precision and throughput, particularly in achieving sub-10nm resolution and handling complex patterns required for advanced semiconductor technology nodes.
Innovation Solution
A charged-particle multi-beam processing apparatus with a pattern definition device featuring an aperture array and deflection array, where apertures are configured to form oblong shapes oriented along the line grid direction, allowing for efficient definition of cut shapes on the target, and a composite aperture array device with interlacing arrays of oblong and non-oblong apertures to handle different line orientations, combined with anisotropic blur projection optics for high-definition cut lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-beam lithography tools use standard aperture shapes (e.g., circular or square) for pattern definition, then the tools can write complex two-dimensional patterns with high precision, but the processing time for one-dimensional circuit designs increases significantly
Solution Approach 1:
The patent applies local quality by using oblong-shaped apertures with specific aspect ratios (e.g., 2:1 or higher) that are optimized for writing cut patterns in one-dimensional circuit designs. This localized geometric modification allows the beam to efficiently write linear features while maintaining the ability to write complex 2D patterns when needed, thus resolving the contradiction between processing speed for 1D designs and pattern complexity capability.
2Productivity
If the aperture array uses only oblong-shaped apertures optimized for one-dimensional patterns, then processing speed for line patterns improves, but the ability to write complex two-dimensional patterns with high precision deteriorates
Solution Approach 1:
The patent implements universality by providing a mixed aperture array that includes both oblong-shaped apertures (for efficient 1D cut pattern writing) and conventional circular or square apertures (for complex 2D pattern writing). This multi-functional aperture array allows the same lithography tool to handle both one-dimensional circuit designs and complex two-dimensional patterns with high precision, resolving the contradiction between processing speed and pattern definition accuracy.
3Manufacturing precision
If multi-beam tools use conventional beam shapes without optimization for cutting patterns, then they can maintain flexibility for various pattern types, but they fail to achieve sub-10nm resolution required for advanced semiconductor nodes
Solution Approach 1:
The patent applies local quality by introducing oblong-shaped apertures with specific aspect ratios that concentrate the beam intensity distribution in a way that achieves sub-10nm resolution for cut patterns. The oblong shape creates a more focused exposure profile along the cut direction while maintaining adequate width for precise line definition, thus achieving the required resolution for advanced semiconductor nodes while preserving pattern writing capability.
4Productivity
If the aperture array is configured with high density to increase throughput, then processing speed improves, but the complexity of controlling and aligning the aperture array increases
Solution Approach 1:
The patent applies segmentation by dividing the aperture array into multiple manageable sub-arrays or groups, where each sub-array can be independently controlled and aligned. This segmentation reduces the overall control complexity while maintaining high density and throughput, as the system can activate only the necessary sub-arrays for each specific writing task rather than managing all apertures simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces processing time and enhances throughput by enabling precise cutting patterns with sub-10nm resolution, meeting the demands of advanced semiconductor technology nodes and allowing for efficient processing of complex patterns.
Implementation Method 1
an electrostatic multi-electrode condenser optics 11c, delivering a broad telecentric charged-particle beam
Implementation Method 2
an aperture array device provided with a multitude of apertures, each of which defines the shape of a respective sub-beam
Implementation Method 3
a deflection array device for deflecting (only) selected sub-beams off their respective nominal path
Implementation Method 4
a demagnifying charged-particle projection optics 16 comprising three lenses
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
In a charged-particle multi-beam processing apparatus for exposure of a target with a plurality of parallel particle-optical columns the beam shaping device of each column includes an aperture array device (203) provided with at least one array of apertures (231, 232). Each array of apertures comprises a multitude of apertures for defining the shape of a respective sub-beam which is then imaged onto the target. The apertures form the sub-beam into an oblong shape as seen along the direction of the beam, said oblong shape having a short (aX) and a long side (aY), with the long side being at least the double of the short side. The oblong shape thus defined by the apertures is oriented traversing a line grid direction of a line pattern of the target. The apertures (231, 232) of different aperture arrays may have different shapes and/or different orientations.