Original citationGhoshal, T., Shaw, M. T., Holmes, J. D. and Morris, M. A. (2016) 'Development of a facile block copolymer method for creating hard mask patterns integrated into semiconductor manufacturing', NanoResearch, 9(10), pp.
ABSTRACT:The aim here is the development of a facile process to create patterns of inorganic oxides and metals on a substrate that can act as hard masks within a lithographic process. These materials should have high etch contrast (to silicon) and so allow high aspect, high fidelity pattern transfer whilst being readily integrate-able in modern semiconductor fabrication (FAB friendly). Here, we show that ultra-small dimension hard masks can be used to develop large areas of densely packed vertically and horizontally orientated Si nanowire arrays. The inorganic and metal hard masks (Ni, NiO and ZnO) of different morphologies and dimensions were formed using microphase separated polystyrene-b-poly(ethylene oxide) (PSb-PEO) block copolymer (BCP) thin films though the variation of BCP molecular weight and the annealing conditions such as temperature, solvent/s etc.. The self-assembled polymer patterns were solvent processed and metal ions included into chosen domains via a selective inclusion method and subsequent inorganic oxide nanopatterns were developed using standard techniques. It is shown by high resolution transmission electron microscopy studies that high aspect pattern transfer could be affected by standard plasma etch techniques. The masking ability of the different materials was compared in order to create the highest quality uniform and smooth sidewall profile of the Si nanowire arrays. Notably, good performance of metal mask was seen and this could impact the use of these materials at small dimension where conventional methods are severely limited.