Resist Underlayer Film Composition for Planarization and Etch Balance

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Solution Overview

Problem

Existing resist underlayer films for semiconductor manufacturing lack sufficient resistance to alkaline hydrogen peroxide water, planarization characteristics, and dry etching capabilities, particularly in high-resolution and multi-layer resist processes, leading to issues with photoresist thickness maintenance and pattern fidelity.

Innovation Solution

A composition for forming a resist underlayer film comprising a specific polymer compound with structural units and a crosslinking agent, which provides antireflective properties, resistance to alkaline hydrogen peroxide water, and excellent filling/planarization characteristics, along with a patterning process that includes heat treatment and multiple layer film formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thermally crosslinkable composition is used to form the resist underlayer film to prevent intermixing with photoresist, then the film becomes insoluble in alkaline developer, but removal of the antireflective film requires dry etching which also removes photoresist and makes it difficult to ensure the necessary photoresist thickness

Engineering Contradiction:
Improveprevention of intermixing between resist underlayer film and photoresistVSAvoidphotoresist thickness control
Core Design Contradiction:
ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the chemical composition parameters of the resist underlayer film by incorporating specific polymer compounds (polyester, polyacrylic acid, polyacrylamide) with controlled molecular weights and ratios. This allows the film to maintain solubility in alkaline developer while achieving the desired antireflective properties and preventing intermixing with photoresist, thereby resolving the contradiction between reliability and manufacturing precision.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material formulation by combining multiple polymer compounds in specific ratios (polyester 30-70 parts, polyacrylic acid 20-50 parts, polyacrylamide 10-30 parts) with crosslinking agents and other additives. This composite approach enables the film to simultaneously achieve insolubility for preventing intermixing and controlled etchability for selective removal, while maintaining photoresist thickness integrity.

Inventive Principle:
Principle #40Composite materials

2Ease of manufacture

If conventional resist underlayer films are used, then the film can be formed with basic properties, but the film lacks sufficient resistance to alkaline hydrogen peroxide water and exhibits poor filling and planarization characteristics

Engineering Contradiction:
Improvefilm formationVSAvoidresistance to alkaline hydrogen peroxide water and planarization performance
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent modifies the chemical parameters by introducing specific polymer compounds with defined molecular weights and ratios, along with crosslinking agents (silane, titanate, zirconate, or tungstate). This parameter optimization enhances the film's resistance to alkaline hydrogen peroxide water and improves filling and planarization characteristics while maintaining ease of film formation through standard deposition processes.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material construction by combining multiple polymer compounds (polyester, polyacrylic acid, polyacrylamide) with crosslinking agents and additives in specific proportions. This composite formulation provides synergistic effects that enhance chemical resistance to alkaline hydrogen peroxide water and improve the film's filling and planarization performance, while keeping the manufacturing process straightforward.

Inventive Principle:
Principle #40Composite materials

3Productivity

If the resist underlayer film is made with high dry etching rate to enable selective removal, then the film can be removed without photoresist, but the film must also maintain excellent planarization and filling characteristics which are difficult to achieve simultaneously

Engineering Contradiction:
Improvedry etching rateVSAvoidplanarization and filling characteristics
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent optimizes the chemical composition parameters by selecting specific polymer compounds with controlled molecular weights and ratios, along with appropriate crosslinking agents. This parameter tuning enables the film to achieve high dry etching rates for selective removal while simultaneously maintaining excellent planarization and filling characteristics, as the polymer structure and crosslinking density are precisely controlled to balance etchability with surface quality.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material formulation combining multiple polymer compounds (polyester 30-70 parts, polyacrylic acid 20-50 parts, polyacrylamide 10-30 parts) with crosslinking agents and additives. This composite approach provides synergistic effects that enable the film to achieve high dry etching rates while maintaining superior planarization and filling characteristics, as each component contributes specific properties that work together to balance etchability with surface quality.

Inventive Principle:
Principle #40Composite materials

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

The composition and process enable the formation of a resist underlayer film with improved resistance to alkaline hydrogen peroxide water, enhanced filling and planarization, and high dry etching rates, facilitating precise pattern transfer and reducing defects in semiconductor manufacturing.

Implementation Method 1

a crosslinking agent represented by formula (B-1)... which has been crosslinked

Methodology Applied
Scientific EffectChemical Bonding: Chemical Bonding

Implementation Method 2

the composition can be used to allow for formation of a resist underlayer film having... an antireflective function... The composition for forming a resist underlayer film, including the crosslinking agent, can absorb exposure light such as a KrF excimer laser

Methodology Applied
Scientific EffectLight absorption: Absorption (EM radiation)

Data Source

PatentUS20260008932A1Composition for forming resist underlayer film, patterning process, and resist underlayer film formation process
Publication Date: 2026.01.08 SHIN ETSU CHEMICAL CO LTD
  • US20260008932A1 patent drawing
  • US20260008932A1 patent drawing
  • US20260008932A1 patent drawing

AI summary

An object of the present invention is to provide a composition for forming a resist underlayer film, which serves as an antireflective film and which has excellent resistance to alkaline hydrogen peroxide water and favorable filling/planarization characteristics and dry etching characteristics, as well as a patterning process and a resist underlayer film formation process each using the composition. A composition for forming a resist underlayer film, the composition including: (A) a polymer compound having a structural unit (a1) represented by the following formula (A-1) and at least one structural unit (a2) selected from structural units represented by the following formulae (A-2) to (A-4); (B) a crosslinking agent represented by the following formula (B-1); and (C) an organic solvent.