Surface-imaging technique for lithographic processes for device fabrication

Claim 2

A process for manufacturing a device comprising: depositing an imaging layer comprising a polymeric resist material on a substrate; exposing a portion of the imaging layer to radiation, thereby forming an exposed region and an unexposed region that together define an image of a pattern in the imaging layer; introducing into the imaging layer a refractory material comprising a silylating reagent that is selectively permeable into one of either the exposed region or the unexposed region of the imaging layer, in combination with about 0.5 volume percent to about 25 volume percent of a silicon-containing cross-linking reagent characterized by the formula: R.sub.n --G--X.sub.m wherein m is greater than or equal to 2, n is greater than or equal to zero, m is at least 2, X is a reactive group that reacts with a functional group pendant to the polymeric resist material, the reaction causing the remaining portion of the cross-linking reagent, R n G to bind to the polymeric resist material, G is a connecting moiety, and R groups are all selected from the group consisting of H and alkyl, wherein the R groups are the same or different, and developing the pattern in the imaging layer.

Claim 3

The process of claim 1 wherein the cross-linking reagent is characterized by the general formula: R.sub.n --Si.sub.a --X.sub.m wherein a is greater than or equal to 1, n is less than or equal to 2a and m is greater than or equal to 2.

Claim 4

The process of claim 1 further comprising depositing a planarizing layer onto the substrate prior to depositing the imaging layer thereon.

Claim 5

The process according to claim 1 wherein the polymeric resist material in the exposed region has pendant functional groups that are susceptible to reaction in significant amounts with the X group.

Claim 6

The process according to claim 1 wherein the polymeric resist material in the unexposed region has pendant functional groups that are susceptible to reaction in significant amounts with the X group.

Claim 7

The process according to claim 2 wherein X is selected from the group consisting of N,N-dimethylamino, N-methylamino, N,N-diethylamino, N-ethylamino, azido, fluoro, chloro, bromo, iodo, cyano and thiocyano.

Claim 8

The process of claim 2 wherein the alkyl groups are selected from the group consisting of ethyl and methyl.

Claim 9

The process of claim 7 wherein the alkyl groups are methyl groups.

Claim 10

The process of claim 2 wherein the image is developed by oxygen plasma etching in a plasma that comprises an oxygen species.

Claim 11

The process of claim 3 wherein the planarizing layer so deposited absorbs radiation of the same wavelength as the wavelength of the radiation to which a portion of the imaging layer is exposed.

Claim 12

The process of claim 3 wherein the planarizing layer so deposited is not substantially permeable by the silylating reagent.

Claim 13

The process of claim 2 wherein the radiation which is used to expose the imaging layer has a wavelength in the ultraviolet range.

Claim 14

The process of claim 2 wherein the radiation which is used to expose the imaging layer has a wavelength in the x-ray range.

Claim 15

The process of claim 2 wherein the cross-linking reagent is selected from the group consisting of 1,2- bis-(N,N-dimethylamino)tetramethyldisilane, bis -(N,N-dimethylamino)methylsilane, and bis-(N,N-dimethylamino)dimethylsilane.

Claim 16

The process of claim 13 wherein the refractory material is combined with about 0.5 to about 10 volume percent cross-linking reagent.

Claim 17

A process for manufacturing a device comprising: obtaining a substrate; depositing a planarizing layer comprising a polymeric resist material substrate; depositing an imaging layer comprising a polymeric resist material with pendant functional groups on the planarizing layer; exposing a portion of the imaging layer to radiation, thereby forming an exposed region and an unexposed region that together define an image of a pattern in the imaging layer; introducing into the imaging layer a refractory material comprising an organodisilane that is selectively permeable into one of either the exposed region or the unexposed region of the imaging layer, the refractory material characterized by the formula: ##STR2## wherein R x is a reactive group that selectively reacts with the functional groups pendant to the polymeric resist material in one of either the exposed region or the unexposed region of the imaging layer, the reaction producing a reactive site with which the remaining portion of the refractory material, SiR A R B SiR C R D R E , reacts, and groups R.sub.(A-E) are all selected from the group consisting of H and CH 3 wherein R.sub.(A-E) are the same or different and wherein at least two of R.sub.(A-E) are CH 3 and wherein the refractory material is combined with a cross-linker having the general formula R.sub.n --Si.sub.a --X.sub.m wherein a is greater than or equal to 1, n is less than or equal to 2a and m is greater than or equal to 2, X is a reactive group that reacts with functional groups pendant to the polymeric resist material and R is selected from the group consisting of H and alkyl, and wherein the cross-linker cross-links at least some of the polymeric resist material; and developing the pattern in the imaging layer.

Claim 18

A process for manufacturing a device comprising: obtaining a substrate; depositing a planarizing layer comprising a polymeric resist material substrate; depositing an imaging layer comprising a polymeric resist material with pendant functional groups on the planarizing layer; exposing a portion of the imaging layer to radiation, thereby forming an exposed region and an unexposed region that together define an image of a pattern in the imaging layer; introducing into the imaging layer a refractory material comprising an organodisilane that is selectively permeable into one of either the exposed region or the unexposed region of the imaging layer, the refractory material characterized by the formula: ##STR2## wherein R x is a reactive group that selectively reacts with the functional groups pendant to the polymeric resist material in one of either the exposed region or the unexposed region of the imaging layer, the reaction producing a reactive site with which the remaining portion of the refractory material, SiR A R B SiR C R D R E , reacts, and groups R.sub.(A-E) are all selected from the group consisting of H and CH 3 wherein R.sub.(A-E) are the same or different and wherein at least two of R.sub.(A-E) are CH 3 and wherein the refractory material is combined with a cross-linker having the general formula R.sub.n --Si.sub.a --X.sub.m wherein a is greater than or equal to 1, n is less than or equal to 2a and m is greater than or equal to 2, X is a reactive group that reacts with functional groups pendant to the polymeric resist material and R is selected from the group consisting of H and alkyl, and wherein the cross-linker cross-links at least some of the polymeric resist material; and developing the pattern in the imaging layer.

Claim 19

The process according to claim 16 wherein the polymeric resist material in the exposed region has pendant functional groups that are susceptible to reaction in significant amounts with the organodisilane.

Claim 20

The process according to claim 16 wherein the polymeric resist material in the unexposed region has pendant functional groups that are susceptible to reaction in significant amounts with the organodisilane.

Claim 21

The process according to claim 16 wherein R x and X are both selected from the group consisting of N,N-dimethylamino, N-methylamino, N,N-diethylamino, N-ethylamino, azido, fluoro, chloro, bromo, iodo, cyano, and thiocyano and wherein R x and X are the same or different but, if different, do not react significantly with each other.

Claim 22

The process of claim 16 wherein the image is developed by etching in a plasma that comprises an oxygen species.

Claim 23

The process of claim 16 wherein the refractory material is combined with about 0.25 to about 25 percent by volume cross-linking reagent.

Claim 24

The process of claim 21 wherein the cross-linking reagent is selected from the group consisting of 1,2- bis-(N,N-dimethylamino)tetramethyldisilane, bis -(N,N-dimethylamino)methylsilane and bis-(N,N-dimethylamino)dimethylsilane.