TW201944490A - 用於圖案化應用的碳硬式遮罩及相關的方法 - Google Patents
用於圖案化應用的碳硬式遮罩及相關的方法 Download PDFInfo
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims description 20
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- 229910003481 amorphous carbon Inorganic materials 0.000 claims abstract description 38
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- 230000003287 optical effect Effects 0.000 claims description 6
- 238000010521 absorption reaction Methods 0.000 claims description 5
- 238000000623 plasma-assisted chemical vapour deposition Methods 0.000 abstract description 6
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- 229910052581 Si3N4 Inorganic materials 0.000 description 2
- 238000010292 electrical insulation Methods 0.000 description 2
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- 239000004065 semiconductor Substances 0.000 description 2
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
- 229910052814 silicon oxide Inorganic materials 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- JBRZTFJDHDCESZ-UHFFFAOYSA-N AsGa Chemical compound [As]#[Ga] JBRZTFJDHDCESZ-UHFFFAOYSA-N 0.000 description 1
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- 229910000577 Silicon-germanium Inorganic materials 0.000 description 1
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 1
- LEVVHYCKPQWKOP-UHFFFAOYSA-N [Si].[Ge] Chemical compound [Si].[Ge] LEVVHYCKPQWKOP-UHFFFAOYSA-N 0.000 description 1
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- 238000007796 conventional method Methods 0.000 description 1
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- 229910021419 crystalline silicon Inorganic materials 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
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- 229910052732 germanium Inorganic materials 0.000 description 1
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Abstract
此處的實施例提供一種使用電漿增強的化學氣相沉積(PECVD)處理沉積非晶碳層之方法,及由此形成的硬式遮罩。在一個實施例中,一種處理基板之方法,包括以下步驟:將基板定位在基板支撐件上,基板支撐件佈置於處理腔室的處理空間中;將包含碳氫化合物氣體及稀釋氣體的處理氣體流至處理空間中;將處理空間維持在小於約100 mTorr的處理壓力下;藉由施加第一功率至處理腔室的一或更多功率電極之一者點燃且維持處理氣體的沉積電漿;將基板支撐件維持在小於約350 °C的處理溫度下;將基板的表面暴露至沉積電漿;及在基板的表面上沉積非晶碳層。
Description
此處所述的實施例大致關於半導體裝置製造的領域,且更具體而言,關於在電子裝置製造處理中使用的非晶碳層及沉積非晶碳層之方法。
非晶碳形成的碳硬式遮罩在半導體裝置製造中使用作為在基板表面或其材料表面層中形成高深寬比開口(例如,2:1或更大的高度對寬度比率)的蝕刻遮罩。一般而言,關於形成高深寬比開口的處理問題,包括堵塞、孔形狀扭曲、圖案變形、頂部關鍵尺寸放大、線彎曲及輪廓折彎,都是傳統沉積的碳硬式遮罩的非所欲材料特性的結果。舉例而言,具有較低材料密度及較低材料堅固(即,楊氏模數)之一者或結合的碳硬式遮罩已知當與具有較高密度或較高堅固的硬式遮罩材料比較時,會造成高深寬比開口增加的變形。類似地,在硬式遮罩材料及其下方佈置的待蝕刻的基板材料之間的較低蝕刻選擇性,以及具有較高膜應力(壓縮或拉伸)的硬式遮罩材料兩者,已知當與使用對下方基板材料具有較高蝕刻選擇性的硬式遮罩材料及較低膜應力的處理比較時,會造成增加的裂縫圖案變形及線彎曲。再者,隨著關鍵尺寸(CD)縮小及高深寬比開口的高度增加,用以形成高深寬比開口的傳統沉積的碳硬式遮罩的厚度亦增加。不幸地,歸因於低光學K及增加的厚度之一者或兩者的具有較低透明度的硬式遮罩在後續光刻處理中可造成對齊問題。對下方基板材料具有較高蝕刻選擇性的硬式遮罩材料與具有較低蝕刻選擇性的硬式遮罩比較,允許減少的厚度,且因此為所欲的。再者,在硬式遮罩材料及下方基板材料之間具有較低蝕刻選擇性的處理通常依賴相對較厚的硬式遮罩,而非所欲地增加沉積的處理時間及成本,導致降低的基板處理能力及增加的裝置成本。
因此,本領域中需要改良的非晶碳硬式遮罩及形成改良的非晶碳硬式遮罩之改良的方法。
本揭露案的實施例大致說明使用電漿增強的化學氣相沉積(PECVD)處理及其上形成的硬式遮罩,將非晶碳層沉積至基板上之方法,包括在基板上先前形成的層上。
在一個實施例中,一種處理基板之方法,包括以下步驟:將基板定位在基板支撐件上,基板支撐件佈置於處理腔室的處理空間中;將包含碳氫化合物氣體及稀釋氣體的處理氣體流至處理空間中;將處理空間維持在小於約100 mTorr的處理壓力下;藉由施加第一功率至處理腔室的一或更多功率電極之一者點燃且維持處理氣體的沉積電漿;將基板支撐件維持在小於約350 °C的處理溫度下;將基板的表面暴露至沉積電漿;及在基板的表面上沉積非晶碳層。
在另一實施例中,一種處理基板之方法,包括以下步驟:將基板定位在基板支撐件上,基板支撐件佈置於處理腔室的處理空間中;將包含碳氫化合物氣體及稀釋氣體的處理氣體流至處理空間中;將處理空間維持在小於約20 mTorr的處理壓力下;藉由施加第一ac功率至該基板支撐件的一或更多功率電極之一者點燃且維持處理氣體的沉積電漿,其中第一ac功率在基板支撐件的基板接收表面每cm2
介於約0.7 W及約15 W之間;將基板支撐件維持在小於約100 °C的處理溫度下;將基板的表面暴露至沉積電漿;及在基板的表面上沉積非晶碳層。
在另一實施例中,一種碳硬式遮罩,包括非晶碳層,佈置於基板的表面上,其中非晶碳層具有大於約1.8 g/cm3
的密度、大於約50 GPa的楊氏模數、小於約500 MPa的膜應力、且在約633 nm的波長下具有小於約0.15的吸收係數(光學K)。
本揭露案的實施例大致關於使用電漿增強的化學氣相沉積(PECVD)處理,用於在基板上沉積非晶碳層之方法,包括在基板上先前形成的層上。具體而言,此處所述的方法提供用於比在沉積非晶碳層的傳統方法中所使用者而言,較低處理壓力,例如小於約100 mTorr,較低處理溫度,例如小於約350 °C,及較高功率,例如大於約1000 W。在此處的某些實施例中,用以點燃且維持沉積電漿的功率輸送至佈置於或耦合至具有基板佈置於其上的基板支撐件的一或更多功率電極。較低處理壓力、較低處理溫度、較高功率及基板位準電漿(透過與基板支撐件的功率電極電容耦合形成的電漿)之各者或結合,增加沉積期間基板表面處的離子能量,而導致當與傳統沉積方法比較時具有sp3含量(類金剛石碳)對sp2含量(類石墨碳)為所欲的較高比率的非晶碳層。因為得到較高的sp3含量,當與傳統沉積的非晶碳層比較時,此處所述的方法提供具有改良的密度、堅固、透明度、蝕刻選擇性及膜應力的非晶碳層。
第1圖根據一個實施例,為用以執行此處所提及之方法的範例處理腔室的概要剖面視圖。可用以執行此處所述之方法的其他範例處理腔室包括由美國加州聖克拉拉市的應用材料公司可取得的Radion®
、Producer®
及SYM3®
處理腔室,以及來自其他製造商的適合的沉積腔室。
處理腔室100包括腔室蓋組件101、一或更多側壁102及腔室底座104。腔室蓋組件101包括腔室蓋106、佈置於腔室蓋106中且電氣耦合的噴淋頭107、及電氣絕緣環108,佈置於腔室蓋106及一或更多側壁102之間。噴淋頭107、一或更多側壁102及腔室底座104一起界定處理空間105。通過腔室蓋106佈置的氣體入口109流體耦合至氣源110。具有通過其佈置的複數個開口111的噴淋頭107用以從氣源110均勻分配處理氣體至處理空間105中。此處,腔室蓋組件101,且因此為噴淋頭107,電氣耦合至接地。在其他實施例中,腔室蓋組件101,及因此佈置於其中的噴淋頭107,電氣耦合至電源供應器(未顯示),例如連續波(CW)RF電源供應器、脈衝RF電源供應器、DC電源供應器、脈衝DC電源供應器或此等之結合,而輸送一或更多偏壓至此。在其他實施例中,處理腔室100不包括噴淋頭107,且處理氣體通過經由腔室蓋106或一或更多側壁102佈置的一或更多氣體入口而輸送至處理空間105。
此處,處理空間105通過真空出口114流體耦合至真空源,例如流體耦合至一或更多專用真空幫浦,而維持處理空間105在次大氣壓條件下且由此排空處理氣體及其他氣體。佈置於處理空間105中的基板支撐件115佈置在可移動支撐桿116上,可移動支撐桿116密封地延伸通過腔室底座104,例如在腔室底座104下方區域中藉由風箱(未顯示)環繞。此處,處理腔室100配置成促進基板117的傳送通過一或更多側壁102之一者中的開口118進出基板支撐件115,此開口118在基板處理期間以門或閥門(未顯示)密封。
通常,佈置於基板支撐件115上的基板117使用加熱器(例如,電阻加熱元件119)及佈置於基板支撐件115中的一或更多冷卻通道120之一者或兩者而維持在所欲處理溫度下。一或更多冷卻通道120流體耦合至冷卻劑源(未顯示),例如具有相對高電阻的修改的水源或製冷劑源。
在某些實施例中,安裝在基板支撐件115的介電材料中或耦合至此的一或更多功率電極(未顯示),經由匹配電路122耦合至一或更多RF或其他ac頻率電源供應器,例如第一電源供應器121A及第二電源供應器121B。此處,沉積電漿123藉由將在處理空間105中的處理氣體與從第一電源供應器121A輸送至此的一或更多功率電極之一者電容耦合而以ac功率在處理空間105中點燃且維持。在某些實施例中,沉積電漿123藉由從第二電源供應器121B輸送的一或更多功率電極之一者以ac功率電容耦合進一步維持。此處,第一電源供應器121A及第二電源供應器121B之各者輸送具有介於約350 kHz及約100 MHz之間的頻率的ac功率,其中來自第一電源供應器121A的功率的頻率不同於來自第二電源供應器121B的頻率。
第2圖根據一個實施例,為在基板的表面上沉積非晶碳層之方法的流程圖。在動作201處,方法200包括將基板定位在基板支撐件上。此處,基板支撐件佈置於處理腔室的處理空間中,例如在第1圖中所述的處理腔室100。在動作202處,方法200包括將處理氣體流至處理空間中。通常,處理氣體包括碳源氣體,例如碳氫化合物氣體,舉例而言CH4
、C2
H2
、C3
H8
、C4
H10
、C2
H4
、C3
H6
、C4
H8
及C5
H10
,或此等之結合,及稀釋氣體,舉例而言鈍氣,例如Ar、He、Ne、Kr或Xe,或此等之結合。在某些實施例中,稀釋氣體包含鈍氣、N2
、H2
,或此等之結合。在某些實施例中,碳氫化合物氣體對稀釋氣體的流率(以下稱比率)之比率介於約1:10及約10:1之間,例如介於約1:5及約5:1之間。舉例而言,在一個實施例中,C2
H2
對He的比率介於約1:3及約3:1之間。在某些實施例中,稀釋氣體包含H2
,且H2
及碳源氣體之間的比率介於約0.5:1及約1:10之間,例如介於約1:1及約1:5之間。在動作203處,方法200包括將處理空間維持在介於約0.1 mTorr及約100 mTorr之間的處理壓力下,例如介於約0.1 mTorr及約50 mTorr之間、介於約0.1 mTorr及約30 mTorr之間、介於約0.1 mTorr及約20 mTorr之間、介於約0.1 mTorr及約15 mTorr之間,舉例而言介於約0.1 mTorr及約10 mTorr之間,或小於約100 mTorr、小於約50 mTorr、小於約20 mTorr、小於約15 mTorr,舉例而言約小於約10 mTorr。
在動作203處,方法200包括藉由施加第一功率至處理腔室的一或更多功率電極之一者來點燃且維持沉積電漿。此處,一或更多功率電極為一或更多頂部電極(例如,處理腔室的腔室蓋或佈置於腔室蓋中的噴淋頭)、一或更多側電極(例如,處理腔室的一或更多側壁)之一者,或為基板支撐件的部分(例如,安裝在或耦合至基板支撐件的介電材料的一或更多電極)。通常,對於尺寸設計成處理300 mm直徑的基板之處理腔室,第一功率為介於約500 W及約8 kW之間,例如介於約1000 W及約5 kW之間。適當的規模可用於經尺寸設計成處理不同尺寸的基板的處理腔室。
在某些實施例中,一或更多功率電極為安裝在或耦合至基板支撐件的介電材料的一者或結合。在某些實施例中,第一功率為RF或其他ac頻率功率,在基板支撐件的基板接收表面每cm2
介於約0.7 W及約11.3 W之間,此處稱W/cm2
,例如介於約1.4 W/cm2
及約7.1 W/cm2
之間,或對於具有經尺寸設計成支撐300 mm直徑的基板的基板支撐表面的基板支撐件,介於約500 W及約5 kW之間,例如介於約1000 W及約5 kW之間。
在某些實施例中,方法200進一步包括施加第二功率至一或更多功率電極之一者,其中第二功率為RF或其他ac頻率功率,介於約0.14 W/cm2
及約7.1 W/cm2
之間,例如介於約0.14 W/cm2
及約3.5 W/cm2
之間,或對於具有經尺寸設計成支撐300 mm直徑的基板的基板支撐表面的基板支撐件,介於約100 W及約5 kW之間,例如介於約100 W及約2.5 kW之間。此處,第二功率的頻率不同於第一功率的頻率。通常,第一功率及第二功率之一者或兩者的頻率為介於約350 kHz及約100 MHz之間,例如約350 KHz、約2 MHz、約13.56 MHz、約27 MHz、約40 MHz、約60 MHz及約100 MHz。在某些實施例中,第一功率及第二功率施加至彼此電氣絕緣的不同功率電極,舉例而言安裝在基板支撐件的介電材料中且藉由介電材料彼此絕緣的雙功率電極。在某些實施例中,第一功率及第二功率使用傳統阻抗匹配電路施加至相同的功率電極。
在動作204處,方法200包括將基板支撐件且因此佈置於其上的基板維持在介於約-50 °C及約350 °C之間的溫度下,例如介於約-50 °C及約150 °C之間、介於約-50 °C及約100 °C之間或介於約-50 °C及約50 °C之間,舉例而言介於約-25 °C及約25 °C之間,或小於約350 °C的溫度,諸如小於約200 °C、小於約150 °C,或小於100 °C,舉例而言小於約50 °C。
在動作205及206處,方法200分別包括將基板的表面暴露至沉積電漿,且在基板的表面上沉積非晶碳層。
第3圖根據一個實施例,圖示根據第2圖中提及之方法所沉積的碳硬式遮罩。在第3圖中,碳硬式遮罩303,此處為圖案化碳硬式遮罩,包括非晶碳層302,具有在其中形成的複數個開口304,而佈置在基板300的待圖案化表面上。通常,基板300或其一或更多材料層以結晶矽、氧化矽、氮氧化矽、氮化矽、應變矽、矽鍺、鎢、氮化鈦、摻雜或未摻雜的多晶矽、碳摻雜的氧化矽、氮化矽、摻雜的矽、鍺、砷化鎵、玻璃、藍寶石及低k介電材料之一者或結合而形成。
此處,非晶碳層具有介於約1 kÅ及約40 kÅ之間的厚度,例如介於約10 kÅ及約40 kÅ之間,舉例而言介於約10 kÅ及約30 kÅ之間,大於約1.8 g/cm3
的密度,大於約50 GPa的楊氏模數,及在約633 nm的波長下為小於約0.15的吸收係數(光學K)。在某些實施例中,非晶碳層具有小於約500 MPa的拉伸或壓縮膜應力。在某些實施例中,非晶碳層具有小於約500 MPa的拉伸膜應力。在某些實施例中,開口304之各者具有大於約2:1的深寬比(高度對寬度),例如大於約3:1、大於約4:1、大於約5:1、大於約6:1、大於約7:1、大於約8:1、大於約9:1,舉例而言大於約10:1。
此處所述的方法提供非晶碳層,及由此形成的碳硬式遮罩,當與傳統沉積的非晶碳層比較時具有改良的密度、堅固、透明度、蝕刻選擇性及應力。再者,此處所述的方法意圖與目前的碳硬式遮罩處理整合方案相容,意味著將方法引入現有裝置製造線將無須在相關的上游或下游處理方法或裝備中作實質改變。
儘管以上導向本揭露案的實施例,可衍生本揭露案的其他及進一步實施例而不會悖離其基本範疇,且其範疇藉由以下申請專利範圍來決定。
100‧‧‧處理腔室
101‧‧‧腔室蓋組件
102‧‧‧側壁
104‧‧‧腔室底座
105‧‧‧處理空間
106‧‧‧腔室蓋
107‧‧‧噴淋頭
108‧‧‧電氣絕緣環
109‧‧‧氣體入口
110‧‧‧氣源
111‧‧‧開口
114‧‧‧真空出口
115‧‧‧基板支撐件
116‧‧‧可移動支撐桿
117‧‧‧基板
118‧‧‧開口
119‧‧‧電阻加熱元件
120‧‧‧冷卻通道
121A‧‧‧第一電源供應器
121B‧‧‧第二電源供應器
122‧‧‧匹配電路
123‧‧‧沉積電漿
200‧‧‧方法
201-206‧‧‧動作
300‧‧‧基板
302‧‧‧非晶碳層
303‧‧‧碳硬式遮罩
304‧‧‧開口
藉由以上所載本揭露案的特徵之方式可詳細理解,而以上簡要概述的本揭露案的更具體說明可藉由參考實施例而獲得,某些實施例圖示於隨附圖式中。然而,應理解,隨附圖式僅圖示本揭露案的通常實施例,且因此不應考量為對範疇之限制,因為本揭露案認可其他均等效果的實施例。
第1圖根據一個實施例,為用以執行此處所提及之方法的範例處理腔室的概要剖面視圖。
第2圖根據一個實施例,為沉積非晶碳層之方法的流程圖。
第3圖根據一個實施例,圖示根據第2圖中提及的方法沉積的非晶碳層所形成的碳硬式遮罩。
國內寄存資訊 (請依寄存機構、日期、號碼順序註記)
無
無
國外寄存資訊 (請依寄存國家、機構、日期、號碼順序註記)
無
無
Claims (20)
- 一種處理一基板之方法,包含以下步驟: 將一基板定位在一基板支撐件上,該基板支撐件佈置於一處理腔室的一處理空間中;將包含一碳氫化合物氣體及一稀釋氣體的一處理氣體流至該處理空間中;將該處理空間維持在小於約100 mTorr的一處理壓力下;藉由施加一第一功率至該處理腔室的一或更多功率電極之一者點燃且維持該處理氣體的一沉積電漿;將該基板支撐件維持在小於約350 °C的一處理溫度下;將該基板的一表面暴露至該沉積電漿;及在該基板的該表面上沉積一非晶碳層。
- 如請求項1所述之方法,其中沉積的該非晶碳層具有大於約1.8 g/cm3 的一密度。
- 如請求項1所述之方法,其中沉積的該非晶碳層具有大於約50 GPa的一楊氏模數。
- 如請求項1所述之方法,其中沉積的該非晶碳層具有小於約500 MPa的一膜應力。
- 如請求項1所述之方法,其中沉積的該非晶碳層在約633 nm的一波長下具有小於約0.15的一吸收係數(光學K)。
- 如請求項1所述之方法,其中沉積的該非晶碳層具有大於約1.8 g/cm3 的一密度、大於約50 GPa的一楊氏模數、小於約500 MPa的一膜應力、且在約633 nm的一波長下具有小於約0.15的一吸收係數(光學K)。
- 如請求項1所述之方法,其中該碳氫化合物氣體包含CH4 、C2 H2 、C3 H8 、C4 H10 、C2 H4 、C3 H6 、C4 H8 、C5 H10 之一者或此等之結合。
- 如請求項7所述之方法,其中碳氫化合物氣體對稀釋氣體的一比率介於約1:10及約10:1之間。
- 如請求項7所述之方法,其中該處理溫度小於約100 °C。
- 如請求項9所述之方法,其中該處理壓力小於約20 mTorr。
- 如請求項10所述之方法,其中該稀釋氣體包含H2 ,且其中該處理氣體中該H2 對碳氫化合物氣體的一比率介於約0.5:1及約1:10之間。
- 如請求項10所述之方法,其中該一或更多功率電極之各者為該基板支撐件的部分。
- 如請求項12所述之方法,其中該第一功率為一ac功率,在該基板支撐件的一基板接收表面每cm2 介於約0.7 W及約11.3 W之間,其中該第一功率具有介於約350 kHz及約100 MHz之間的一頻率。
- 如請求項13所述之方法,進一步包含以下步驟:施加一第二功率至該一或更多功率電極之一者,其中該第二功率為一ac功率,在該基板支撐件的該基板接收表面每cm2 介於約0.14 W及約11.3 W之間,其中該第二功率具有介於約350 kHz及約100 MHz之間的一頻率,且其中該第一功率的該頻率不同於該第二功率的該頻率。
- 一種處理一基板之方法,包含以下步驟: 將一基板定位在一基板支撐件上,該基板支撐件佈置於一處理腔室的一處理空間中;將包含一碳氫化合物氣體及一稀釋氣體的一處理氣體流至該處理空間中;將該處理空間維持在小於約20 mTorr的一處理壓力下;藉由施加一第一ac功率至該基板支撐件的一或更多功率電極之一者點燃且維持該處理氣體的一沉積電漿,其中該第一ac功率在該基板支撐件的一基板接收表面每cm2 介於約0.7 W及約15 W之間;將該基板支撐件維持在小於約100 °C的一處理溫度下;將該基板的一表面暴露至該沉積電漿;及在該基板的該表面上沉積一非晶碳層。
- 如請求項15所述之方法,其中該碳氫化合物氣體包含CH4 、C2 H2 、C3 H8 、C4 H10 、C2 H4 、C3 H6 、C4 H8 、C5 H10 之一者或此等之結合。
- 如請求項16所述之方法,其中該稀釋氣體包含H2 ,且其中該處理氣體中該H2 對碳氫化合物氣體的一比率介於約0.5:1及約1:10之間。
- 如請求項15所述之方法,進一步包含以下步驟:施加一第二ac功率至該基板支撐件的該一或更多功率電極之一者,其中該第二ac功率在該基板支撐件的該基板接收表面每cm2 介於約0.14 W及約7.1 W之間,其中該第一ac功率及該第二ac功率具有介於約350 kHz及約100 MHz之間的一頻率,且其中該第一ac功率的該頻率不同於該第二ac功率的該頻率。
- 一種碳硬式遮罩,包含: 一非晶碳層,佈置於一基板的一表面上,其中該非晶碳層具有大於約1.8 g/cm3 的一密度、大於約50 GPa的一楊氏模數、小於約500 MPa的一膜應力、且在約633 nm的一波長下具有小於約0.15的一吸收係數(光學K)。
- 如請求項19所述之碳硬式遮罩,其中該非晶碳層具有穿過其形成的複數個開口,且其中該複數個開口之各者具有大於約2:1的一高度對寬度比率。
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