US20140329057A1 - Photo-curable composition and patterning method - Google Patents

Photo-curable composition and patterning method Download PDF

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US20140329057A1
US20140329057A1 US14/366,458 US201214366458A US2014329057A1 US 20140329057 A1 US20140329057 A1 US 20140329057A1 US 201214366458 A US201214366458 A US 201214366458A US 2014329057 A1 US2014329057 A1 US 2014329057A1
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photo
curable composition
group
meth
acrylate
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Naoko Matsufuji
Toshiki Ito
Kanae Kawahata
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Canon Inc
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Canon Inc
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Assigned to CANON KABUSHIKI KAISHA reassignment CANON KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KAWAHATA, Kanae, ITO, TOSHIKI, MATSUFUJI, Naoko
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    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/0002—Lithographic processes using patterning methods other than those involving the exposure to radiation, e.g. by stamping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/026—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing of layered or coated substantially flat surfaces
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2/00—Processes of polymerisation
    • C08F2/46—Polymerisation initiated by wave energy or particle radiation
    • C08F2/48—Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light
    • C08F2/50—Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light with sensitising agents
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • G03F7/0045—Photosensitive materials with organic non-macromolecular light-sensitive compounds not otherwise provided for, e.g. dissolution inhibitors
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/26—Processing photosensitive materials; Apparatus therefor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/26—Bombardment with radiation
    • H01L21/263—Bombardment with radiation with high-energy radiation
    • H01L21/265—Bombardment with radiation with high-energy radiation producing ion implantation
    • H01L21/266—Bombardment with radiation with high-energy radiation producing ion implantation using masks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/18—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H01L21/302—Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to change their surface-physical characteristics or shape, e.g. etching, polishing, cutting
    • H01L21/306—Chemical or electrical treatment, e.g. electrolytic etching
    • H01L21/308—Chemical or electrical treatment, e.g. electrolytic etching using masks
    • H01L21/3081—Chemical or electrical treatment, e.g. electrolytic etching using masks characterised by their composition, e.g. multilayer masks, materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3425—Printed circuits
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Definitions

  • the present invention relates to a photo-curable composition and a patterning method using the photo-curable composition.
  • the UV imprint method includes pressing a mold having a fine textured pattern against a substrate coated with a photo-curable composition to transfer the textured pattern to the photo-curable composition film on the substrate.
  • a mold transparent to exposure light is pressed against a photo-curable composition applied to a substrate, and the photo-curable composition is cured by photoirradiation. After removal of the mold, a photo-cured product having a fine textured pattern on the substrate can be obtained.
  • One known photo-curable composition for use in such a UV imprint method contains a polymerizable monomer and a photopolymerization initiator (PTL 1).
  • the present invention provides a photo-curable composition having a high polymerization rate and a high polymerization conversion.
  • the present invention also provides a patterning method having a high throughput.
  • a photo-curable composition according to one aspect of the present invention contains a radical-polymerizable monomer (A), a photopolymerization initiator (B), and a compound (C) serving as a sensitizer and having the following general formula (1):
  • X1 and X2 are independently selected from the group consisting of a hydrogen atom, substituted and unsubstituted alkyl groups, and substituted and unsubstituted aryl groups.
  • R1 to R10 are independently selected from the group consisting of a hydrogen atom, halogen atoms, substituted and unsubstituted alkyl groups, substituted and unsubstituted alkoxy groups, and substituted and unsubstituted aryl groups.
  • X1 and X2 may be combined together to form a ring.
  • a patterning method for forming a pattern of a photo-cured product on a substrate to be processed includes placing the photo-curable composition on the substrate to be processed, bringing the photo-curable composition into contact with a mold, irradiating the photo-curable composition with light to cure the photo-curable composition, and releasing the photo-cured product from the mold after the irradiation.
  • the present invention provides a photo-curable composition having a high polymerization rate and a high polymerization conversion.
  • the present invention also provides a patterning method having a high throughput.
  • FIGS. 1A to 1F are cross-sectional views illustrating a patterning method according to an embodiment of the present invention.
  • FIG. 2 is a schematic view illustrating attenuated total reflection infrared spectroscopy utilizing a photoirradiation mechanism.
  • FIG. 3 is a graph of the polymerization conversion of photo-curable compositions (a-1 and b-1 to b-6) irradiated with light having a wavelength of 365 ⁇ 5 nm at an illuminance of 1 mW/cm 2 .
  • FIG. 4 is a table of the half decay exposure of a peak ascribed to an acryl group of photo-curable compositions (a-1 and b-1 to b-6) irradiated with light having a wavelength of 365 ⁇ 5 nm at an illuminance of 1 mW/cm 2 .
  • FIG. 5 is a graph of the polymerization conversion of photo-curable compositions (a-2, b-7, and b-8) irradiated with light having a wavelength of 313 ⁇ 5 nm at an illuminance of 1 mW/cm 2 .
  • FIG. 6 is a table of the half decay exposure of a peak ascribed to an acryl group of photo-curable compositions (a-2, b-7, and b-8) irradiated with light having a wavelength of 313 ⁇ 5 nm at an illuminance of 1 mW/cm 2 .
  • FIG. 7 is a graph of the polymerization conversion of photo-curable compositions (a-3 and b-9) irradiated with light having a wavelength of 313 ⁇ 5 nm at an illuminance of 1 mW/cm 2 .
  • FIG. 8 is a table of the half decay exposure of a peak ascribed to an acryl group of photo-curable compositions (a-3 and b-9) irradiated with light having a wavelength of 313 ⁇ 5 nm at an illuminance of 1 mW/cm 2 .
  • the term “patterning method”, as used herein, includes a UV imprint method.
  • the UV imprint method is preferably defined as a method for forming a pattern having a size in the range of 1 nm to 10 mm, more preferably approximately 10 nm to 100 ⁇ m.
  • a technique of forming a nanoscale (1 to 100 nm) pattern (textured structure) is generally referred to as UV nanoimprint.
  • the present invention includes UV nanoimprint.
  • a photo-curable composition according to an embodiment of the present invention contains a radical-polymerizable monomer (A), a photopolymerization initiator (B), and a sensitizer (C).
  • the photo-curable composition may contain another additive component. These components will be described in detail below.
  • the radical-polymerizable monomer (A) of a photo-curable composition according to an embodiment of the present invention may have at least one acryloyl or methacryloyl group.
  • radical-polymerizable monomer examples include, but are not limited to, phenoxyethyl (meth)acrylate, phenoxy-2-methylethyl (meth)acrylate, phenoxyethoxyethyl (meth)acrylate, 3-phenoxy-2-hydroxypropyl (meth)acrylate, 2-phenylphenoxyethyl (meth)acrylate, 4-phenylphenoxyethyl (meth)acrylate, 3-(2-phenylphenyl)-2-hydroxypropyl (meth)acrylate, EO-modified p-cumylphenol (meth)acrylate, 2-bromophenoxyethyl (meth)acrylate, 2,4-dibromophenoxyethyl (meth)acrylate, 2,4,6-tribromophenoxyethyl (meth)acrylate, EO-modified phenoxy (meth)acrylate, PO-modified phenoxy (meth)acrylate, polyoxyethylene nonylphen
  • the monofunctional (meth)acryl compound may be the following product:
  • Aronix M101, M102, M110, M111, M113, M117, M5700, TO-1317, M120, M150, or M156 (manufactured by Toagosei Co., Ltd.), MEDOL 10, MIBDOL 10, CHDOL 10, MMDOL 30, MEDOL 30, MIBDOL 30, CHDOL 30, LA, IBXA, 2-MTA, HPA, or Viscoat #150, #155, #158, #190, #192, #193, #220, #2000, #2100, or #2150 (manufactured by Osaka Organic Chemical Industry Ltd.), Light Acrylate BO-A, EC-A, DMP-A, THF-A, HOP-A, HOA-MPE, HOA-MPL, PO-A, P-200A, NP-4EA, or NP-BEA, or epoxy ester M-600A (manufactured by Kyoeisha Chemical Co., Ltd.), Kayarad TC110S, R-564, or R-128H
  • Examples of a polyfunctional (meth)acryl compound having at least two acryloyl or methacryloyl groups include, but are not limited to, trimethylolpropane di(meth)acrylate, trimethylolpropane tri(meth)acrylate, EO-modified trimethylolpropane tri(meth)acrylate, PO-modified trimethylolpropane tri(meth)acrylate, EO,PO-modified trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, ethylene glycol di(meth)acrylate, tetra(ethylene glycol) di(meth)acrylate, poly(ethylene glycol) di(meth)acrylate, poly(propylene glycol) di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di
  • the polyfunctional (meth)acryl compound may be the following product: Yupimer UV SA1002 or SA2007 (manufactured by Mitsubishi Chemical Corp.), Viscoat #195, #230, #215, #260, #335HP, #295, #300, #360, #700, GPT, or 3PA (manufactured by Osaka Organic Chemical Industry Ltd.), Light Acrylate 4EG-A, 9EG-A, NP-A, DCP-A, BP-4EA, BP-4PA, TMP-A, PE-3A, PE-4A, or DPE-6A (manufactured by Kyoeisha Chemical Co., Ltd.), Kayarad PET-30, TMPTA, R-604, DPHA, DPCA-20, -30, -60, or -120, HX-620, D-310, or D-330 (manufactured by Nippon Kayaku Co., Ltd.), Aronix M208, M210, M215, M220, M240, M305, M309, M
  • radical-polymerizable monomers may be used alone or in combination.
  • (meth)acrylate refers to an acrylate or its corresponding methacrylate.
  • (meth)acryloyl group refers to an acryloyl group or its corresponding methacryloyl group.
  • EO denotes ethylene oxide
  • an EO-modified compound has a block structure of an ethylene oxide group.
  • PO denotes propylene oxide
  • a PO-modified compound has a block structure of a propylene oxide group.
  • hydrogenated refers to the addition of hydrogen atoms to a C ⁇ C double bond, for example, of a benzene ring.
  • the photopolymerization initiator (B) may be a photo radical generator.
  • photo radical generator refers to a polymerization initiator that can generate a radical when induced by light (a radiation, for example, infrared light, visible light, ultraviolet light, far-ultraviolet light, an X-ray, or a charged particle beam, such as an electron beam).
  • light a radiation, for example, infrared light, visible light, ultraviolet light, far-ultraviolet light, an X-ray, or a charged particle beam, such as an electron beam.
  • Photo radical generators can generate a radical in a chemical reaction caused by photoirradiation and initiate a radical polymerization.
  • photo radical generator examples include, but are not limited to,
  • 2,4,5-triarylimidazole dimers such as a 2-(o-chlorophenyl)-4,5-diphenylimidazole dimer, a 2-(o-chlorophenyl)-4,5-di(methoxyphenyl)imidazole dimer, a 2-(o-fluorophenyl)-4,5-diphenylimidazole dimer, and a 2-(o- or p-methoxyphenyl)-4,5-diphenylimidazole dimer,
  • 2,4,5-triarylimidazole dimers such as a 2-(o-chlorophenyl)-4,5-diphenylimidazole dimer, a 2-(o-chlorophenyl)-4,5-di(methoxyphenyl)imidazole dimer, a 2-(o-fluorophenyl)-4,5-diphenylimidazole dimer, and a 2-(o- or p-methoxyphenyl)
  • benzophenone and benzophenone derivatives such as N,N′-tetramethyl-4,4′-diaminobenzophenone (Michler's ketone), N,N′-tetraethyl-4,4′-diaminobenzophenone, 4-methoxy-4′-dimethylaminobenzophenone, 4-chlorobenzophenone, 4,4′-dimethoxybenzophenone, and 4,4′-diaminobenzophenone,
  • aromatic ketone derivatives such as 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1,2-methyl-1-[4-(methylthio)phenyl]-2-morpholino-propanon-1-one,
  • quinones such as 2-ethylanthraquinone, phenanthrenequinone, 2-t-butylanthraquinone, octamethylanthraquinone, 1,2-benzanthraquinone, 2,3-benzanthraquinone, 2-phenylanthraquinone, 2,3-diphenylanthraquinone, 1-chloroanthraquinone, 2-methylanthraquinone, 1,4-naphthoquinone, 9,10-phenanthrenequinone, 2-methyl-1,4-naphthoquinone, and 2,3-dime thylanthraquinone,
  • benzoin ether derivatives such as benzoin methyl ether, benzoin ethyl ether, and benzoin phenyl ether,
  • benzoin and benzoin derivatives such as methylbenzoin, ethylbenzoin, and propylbenzoin
  • benzyl derivatives such as benzyl dimethyl ketal
  • acridine derivatives such as 9-phenylacridine and 1,7-bis(9,9′-acridinyl)heptane
  • acetophenone and acetophenone derivatives such as 3-methylacetophenone, acetophenone benzyl ketal, 1-hydroxycyclohexyl phenyl ketone, and 2,2-dimethoxy-2-phenylacetophenone,
  • thioxanthone and thioxanthone derivatives such as diethylthioxanthone, 2-isopropylthioxanthone, and 2-chlorothioxanthone,
  • xanthone fluorenone, benzaldehyde, fluorene, anthraquinone, triphenylamine, carbazole, 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one, and 2-hydroxy-2-methyl-1-phenyl-propan-1-one, and
  • photo radical generators may be used alone or in combination.
  • the photo radical generator may be one selected from the group consisting of 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1,2,2-dimethoxy-2-phenylacetophenone, and 2-hydroxy-2-methyl-1-phenyl-propan-1-one.
  • the photo radical generator may be, but is not limited to, the following product:
  • the photopolymerization initiator (B) component constitutes 0.01% by weight or more and 10% by weight or less, preferably 0.1% by weight or more and 7% by weight or less, of the amount of radical-polymerizable monomer (A). Less than 0.01% by weight may result in a decreased curing rate and low reaction efficiency. On the other hand, more than 10% by weight may result in poor mechanical characteristics of a cured product of the photo-curable composition.
  • the sensitizer (C) in the present invention has the following general formula (1).
  • X1 and X2 are independently selected from the group consisting of a hydrogen atom, substituted and unsubstituted alkyl groups, and substituted and unsubstituted aryl groups.
  • X1 and X2 may be the same or different. X1 and X2 may be combined together to form a ring.
  • alkyl group in X1 and X2 examples include, but are not limited to, a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a t-butyl group, a sec-butyl group, an octyl group, a cyclohexyl group, a 1-adamantyl group, and a 2-adamantyl group.
  • Examples of the aryl group in X1 and X2 include, but are not limited to, a phenyl group, a naphthyl group, an indenyl group, a biphenyl group, a terphenyl group, and a fluorenyl group.
  • X1 and X2 may be independently selected from the group consisting of a hydrogen atom, alkyl groups, a phenyl group, a naphthyl group, and alkyl groups in which part or all of the hydrogen atoms are substituted with fluorine.
  • Part or all of the hydrogen atoms of each of the alkyl groups and the aryl groups may be substituted with fluorine.
  • R1 to R10 are independently selected from the group consisting of a hydrogen atom, halogen atoms, substituted and unsubstituted alkyl groups, substituted and unsubstituted alkoxy groups, and substituted and unsubstituted aryl groups.
  • R1 to R10 may be the same or different.
  • halogen atoms in R1 to R10 include, but are not limited to, fluorine, chlorine, bromine, and iodine.
  • alkyl group in R1 to R10 examples include, but are not limited to, a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a t-butyl group, a sec-butyl group, an octyl group, a cyclohexyl group, a 1-adamantyl group, and a 2-adamantyl group.
  • alkoxy group in R1 to R10 examples include, but are not limited to, a methoxy group, an ethoxy group, a propoxy group, a 2-ethyl-octyloxy group, and a benzyloxy group.
  • Examples of the aryl group in R1 to R10 include, but are not limited to, a phenyl group, a naphthyl group, an indenyl group, a biphenyl group, a terphenyl group, and a fluorenyl group.
  • substituents of the substituted alkyl groups, the substituted alkoxy groups, and the substituted aryl groups include, but are not limited to, alkyl groups, such as a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, and a t-butyl group, aralkyl groups, such as a benzyl group, aryl groups, such as a phenyl group and a biphenyl group, heterocyclic groups, such as a pyridyl group and a pyrrolyl group, amino groups, such as a dimethylamino group, a diethylamino group, a dibenzylamino group, a diphenylamino group, and a ditolylamino group, alkoxy groups, such as a methoxy group, an ethoxy group, and a propoxy group, aryloxy groups, such as
  • Part or all of the hydrogen atoms of each of the alkyl groups, the alkoxy groups, and the aryl groups may be substituted with fluorine.
  • R1 to R10 may be independently selected from the group consisting of a hydrogen atom, halogen atoms, alkyl groups, alkoxy groups, a phenyl group, a naphthyl group, and alkyl groups in which part or all of the hydrogen atoms are substituted with fluorine.
  • the present inventors found that a compound having the general formula (1) can improve the curing of a photo-curable composition containing a radical-polymerizable monomer and a photopolymerization initiator as compared with generally known sensitizers.
  • the present invention provides a photo-curable composition having a higher polymerization rate and a higher polymerization conversion than before.
  • the compound having the general formula (1) can serve as a sensitizer and undergo a photoreaction through irradiation with ultraviolet light to form a hydrogen donor.
  • the hydrogen donor produced by the photoreaction of the sensitizer can react with a radical produced from the photopolymerization initiator through optical absorption.
  • the resulting hydrogen donor radical can initiate the polymerization reaction of the monomer.
  • the sensitizer absorbs light, and the energy or an electron of the sensitizer is transferred to the photopolymerization initiator to convert the photopolymerization initiator into a radical, thereby initiating the polymerization reaction of the monomer.
  • a photo-curable composition according to an embodiment of the present invention can be used as a suitable shape transfer layer in patterning techniques using a mold, such as UV nanoimprint.
  • anisoin N-cyclohexyl carbamate having the following general formula (2).
  • the sensitizer in a photo-curable composition according to an embodiment of the present invention preferably constitutes 0% to 20% by weight, more preferably 0.1% to 5.0% by weight, still more preferably 0.2% to 2.0% by weight, of the amount of radical-polymerizable monomer (A).
  • the sensitizer content is 0.1% by weight or more, the effects of the sensitizer can be more effectively produced.
  • the sensitizer content is 5% by weight or less, a photo-cured product can have a sufficiently high molecular weight, and deterioration in solubility or storage stability can be prevented.
  • a photo radical generator for use in combination with the compound (C) serving as a sensitizer and having the general formula (1) may be selected from the group consisting of 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1 having the following general formula (3), 2,2-dimethoxy-2-phenylacetophenone having the following general formula (4), and 2-hydroxy-2-methyl-1-phenyl-propan-1-one having the following general formula (5).
  • the structural formulae of these compounds are described below.
  • a photo-curable composition according to an embodiment of the present invention may contain other additive components, such as a sensitizer, an antioxidant, a solvent, and/or a polymer component, for each purpose without losing the advantages of the present invention.
  • a photo-curable composition according to an embodiment of the present invention may be mixed and dissolved at a temperature in the range of 0° C. to 100° C.
  • a photo-curable composition according to an embodiment of the present invention preferably has a viscosity in the range of 1 to 100 cP, more preferably 5 to 50 cP, still more preferably 6 to 20 cP, at 23° C. in the absence of solvent.
  • a viscosity of more than 100 cP may result in a long filling time of the composition in a micropatterned depressed portion on a mold or patterning defects because of insufficient filling in a mold contact step described below.
  • a viscosity of less than 1 cP may result in uneven coating in a coating step described below or the outflow of the composition from a mold in the mold contact step described below.
  • a photo-curable composition according to an embodiment of the present invention preferably has a surface tension in the range of 5 to 70 mN/m, more preferably 7 to 35 mN/m, still more preferably 10 to 32 mN/m, at 23° C. in the absence of solvent.
  • a surface tension of less than 5 mN/m results in a long filling time of the composition in recessed and raised portions on a mold in the mold contact step described below.
  • a surface tension of more than 70 mN/m results in poor surface smoothness.
  • a photo-curable composition according to an embodiment of the present invention may be passed through a filter having a pore size in the range of 0.001 to 5.0 ⁇ m. The filtration may be performed in multiple steps or multiple times. A filtered liquid may be filtered again.
  • the material of the filter may be, but is not limited to, polyethylene resin, polypropylene resin, fluoropolymer, or nylon resin.
  • the concentration of metal impurities in a photo-curable composition according to an embodiment of the present invention is preferably 10 ppm or less, more preferably 100 ppb or less.
  • a patterning method involves a placing step of placing a photo-curable composition on a substrate to be processed ( FIG. 1A ), a mold contact step of bringing the photo-curable composition into contact with a mold having recessed and raised portions ( FIG. 1B ), a photoirradiation step of irradiating the photo-curable composition with light for curing while the photo-curable composition is in contact with the mold ( FIG. 1C ), and a demolding step of releasing the photo-cured product from the mold ( FIG. 1D ).
  • the photo-curable composition may be irradiated with light through the mold.
  • the method may further involve an exposure step of etching part of a film of the photo-curable composition remaining in depressed portions after the demolding step to expose a surface of the substrate in the depressed portions ( FIG. 1E ).
  • the placing step of placing a photo-curable composition on a substrate to be processed is a coating step.
  • a photo-curable composition according to an embodiment of the present invention is applied to a substrate to be processed.
  • the substrate to be processed may be a silicon wafer.
  • the substrate to be processed may also be a substrate for semiconductor devices made of aluminum, a titanium-tungsten alloy, an aluminum-silicon alloy, an aluminum-copper-silicon alloy, silicon oxide, or silicon nitride.
  • the substrate to be processed may be subjected to surface treatment, such as silane coupling treatment, silazane treatment, or the formation of an organic film, to improve adhesion to the photo-curable composition.
  • the photo-curable composition may be applied by an ink jet method, a dip coating method, an air knife coating method, a curtain coating method, a wire bar coating method, a gravure coating method, an extrusion coating method, a spin coating method, or a slit scanning method.
  • the film thickness of the photo-curable composition depends on the application and is in the range of 0.01 to 100.0 ⁇ m, for example.
  • recessed and raised portions (micropattern) on a surface of the mold are filled with the photo-curable composition.
  • the mold is made of an optically transparent material, for example, glass, quartz, an optically transparent resin, such as PMMA or polycarbonate resin, a transparent metallized film, a soft film, such as a polydimethylsiloxane film, a photo-cured film, or a metal film.
  • an optically transparent material for example, glass, quartz, an optically transparent resin, such as PMMA or polycarbonate resin, a transparent metallized film, a soft film, such as a polydimethylsiloxane film, a photo-cured film, or a metal film.
  • a surface of the mold in contact with the photo-curable composition may be hydrophilic so as to facilitate the formation of a polar bond with a fluorine-containing surfactant.
  • a mold for use in a patterning method according to an embodiment of the present invention may be subjected to surface treatment so as to improve the releasability of a photo-curable composition from the mold.
  • the surface treatment may involve the use of a silane coupling agent, such as a silicon or fluorinated coupling agent, for example, a commercially available coating-type mold-release agent, such as Optool DSX manufactured by Daikin Industries, Ltd.
  • the contact pressure is generally, but not limited to, in the range of 0.1 to 100 MPa, preferably 0.1 to 50 MPa, more preferably 0.1 to 30 MPa, still more preferably 0.1 to 20 MPa.
  • the contact time is generally, but not limited to, in the range of 1 to 600 seconds, preferably 1 to 300 seconds, more preferably 1 to 180 seconds, still more preferably 1 to 120 seconds.
  • a patterning method according to an embodiment of the present invention may be performed in the atmosphere, under reduced pressure, or in an inert gas atmosphere.
  • inert gas include, but are not limited to, nitrogen, carbon dioxide, helium, argon, various chlorofluorocarbons, and mixtures thereof.
  • the pressure may be in the range of 0.0001 to 10 atm.
  • Use of reduced pressure or an inert gas atmosphere can eliminate the effects of oxygen or water on the photo-curing reaction.
  • the photo-curable composition is irradiated with light while the photo-curable composition is in contact with the mold.
  • the photo-curable composition in recessed and raised portions on the mold surface is cured.
  • the light is not particularly limited, depends on the sensitive wavelength of a photo-curable composition according to an embodiment of the present invention, and may be ultraviolet light having a wavelength in the range of approximately 150 to 400 nm, X-rays, or an electron beam
  • Various photosensitive compounds sensitive to ultraviolet light are easily available as the polymerization initiator (B).
  • Examples of ultraviolet light sources include, but are not limited to, high-pressure mercury lamps, ultrahigh-pressure mercury lamps, low-pressure mercury lamps, deep-UV lamps, carbon arc lamps, chemical lamps, metal halide lamps, xenon lamps, KrF excimer lasers, ArF excimer lasers, and F 2 excimer lasers. These light sources may be used alone or in combination.
  • the photo-curable composition may be entirely or partly irradiated with light.
  • the photo-curable composition may further be cured with heat.
  • the heating atmosphere and the heating temperature of heat curing are not particularly limited and may be an inert atmosphere or under reduced pressure and in the range of 40° C. to 200° C. Heating may be performed with a hot plate, an oven, or a furnace.
  • a patterning method according to the present embodiment is performed under such conditions that the polymerization rate and the polymerization conversion of the radical-polymerizable monomer (A) can be improved with the sensitizer (C).
  • the present embodiment can improve throughput and curing, as well as polymerization rate and polymerization conversion.
  • the polymerization rate and the polymerization conversion of the radical-polymerizable monomer (A) greatly depend on the combination of the radical-polymerizable monomer (A) with the photopolymerization initiator (B) and the sensitizer (C).
  • the polymerization rate and the polymerization conversion of the radical-polymerizable monomer (A) also depend on the spectral sensitivity of the photopolymerization initiator (B) for irradiation light.
  • antioxidant can affect polymerization rate and polymerization conversion and should take it into account.
  • the polymerization rate and the polymerization conversion of the radical-polymerizable monomer (A) can be measured by attenuated total reflection infrared spectroscopy utilizing a photoirradiation mechanism as illustrated in FIG. 2 . Several to several tens of infrared spectra per second can be taken during photoirradiation.
  • the photo-curable composition is removed from the mold.
  • the reverse pattern of the recessed and raised portions on the mold surface is transferred to a cured product of the photo-curable composition.
  • a substrate to be processed may be fixed while a mold may be moved away from the substrate to be processed, or a mold may be fixed while a substrate to be processed may be moved away from the mold, or a substrate to be processed and a mold may be moved in the opposite directions.
  • a patterning method may involve the use of a coating-type mold-release agent. More specifically, a coating-type mold-release agent layer may be formed on a patterned surface of a mold before the mold contact step.
  • coating-type mold-release agent examples include, but are not limited to, silicon mold-release agents, fluorinated mold-release agents, polyethylene mold-release agents, polypropylene mold-release agents, paraffinic mold-release agents, montan mold-release agents, and carnauba mold-release agents. These mold-release agents may be used alone or in combination.
  • part of a film of the photo-curable composition remaining in depressed portions is etched to expose a surface of the substrate in the depressed portions.
  • the etching method is not particularly limited and may be a conventional method, such as dry etching.
  • a known dry etching apparatus may be used in dry etching.
  • the source gas for dry etching depends on the elementary composition of a film to be etched and may be an oxygen-containing gas, such as O 2 , CO, or CO 2 , an inert gas, such as He, N 2 , or Ar, a chlorine gas, such as Cl 2 or BCl 3 , H 2 , or NH 3 . These source gases may be used alone or in combination.
  • a pattern formed in the exposure step can be used as a film for an interlayer insulating film of a semiconductor element, such as LSI, system LSI, DRAM, SDRAM, RDRAM, or D-RDRAM, or a resist film in the manufacture of a semiconductor element.
  • a semiconductor element such as LSI, system LSI, DRAM, SDRAM, RDRAM, or D-RDRAM, or a resist film in the manufacture of a semiconductor element.
  • the exposed portions in the exposure step may be subjected to etching or ion implantation to form a circuit structure based on the photo-curable composition pattern on the substrate to be processed.
  • a circuit board for a semiconductor element can be manufactured through these steps.
  • the photo-curable composition pattern may be removed from the substrate or may be left as a member for constituting the element.
  • the substrate may be used as an optical element having a textured pattern on its surface. More specifically, the substrate may be provided as an article that includes the substrate and a cured product of the photo-curable composition on the substrate.
  • a photo-curable composition (a-1) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 369 (2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1, manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component anisoin N-cyclohexyl carbamate (ANC-101, manufactured by Midori Kagaku Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 369 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1, manufactured by Ciba Japan K.K.
  • ANC-101 anisoin N-cyclohexyl carbamate
  • Approximately 1 ⁇ L of the photo-curable composition (a-1) was dropped on a diamond ATR crystal on an attenuated total reflection infrared spectrometer Nicolet 6700 (manufactured by Thermofisher Scientific) and was covered with a quartz glass having a thickness of 1 mm ( FIG. 2 ).
  • the photo-curable composition (a-1) was irradiated with light from a UV light source EX250 (manufactured by Hoyacandeo Optronics Corporation) equipped with a 250-W ultrahigh-pressure mercury lamp through the quartz glass and an interference filter VPF-25C-10-25-36500 (manufactured by Sigmakoki Co., Ltd.).
  • the light had a wavelength of 365 ⁇ 5 nm and an illuminance of 1 mW/cm 2 .
  • the measurement of attenuated total reflection infrared spectra was started simultaneously with photoirradiation. Data was acquired 9.7 times per second during photoirradiation.
  • FIG. 3 is a graph of the polymerization conversion of photo-curable compositions (a-1 and b-1 to b-6) as a function of time.
  • the polymerization conversion was calculated from the peak intensity at 810 cm ⁇ 1 ascribed to the acryl group of HDODA.
  • the inclination at the rising portion represents the polymerization rate.
  • FIG. 4 is a table of the half decay exposure of the peak intensity at 810 cm ⁇ 1 ascribed to the acryl group of HDODA.
  • a photo-curable composition (a-2) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 651 (2,2-dimethoxy-2-phenylacetophenone, manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component anisoin N-cyclohexyl carbamate (ANC-101, manufactured by Midori Kagaku Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 651 2,2-dimethoxy-2-phenylacetophenone, manufactured by Ciba Japan K.K.
  • ANC-101 anisoin N-cyclohexyl carbamate
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 1 except that the irradiation light wavelength was changed to 313 ⁇ 5 nm with an interference filter VPF-25C-10-15-31300 (manufactured by Sigmakoki Co., Ltd.).
  • FIG. 5 is a graph of the polymerization conversion of photo-curable compositions (a-2, b-7, and b-8) as a function of time.
  • the polymerization conversion was calculated from the peak intensity at 810 cm ⁇ 1 ascribed to the acryl group of HDODA.
  • FIG. 6 is a table of the half decay exposure of the peak intensity at 810 cm ⁇ 1 ascribed to the acryl group of HDODA.
  • a photo-curable composition (a-3) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 3 parts by weight of the (B) component Darocur 1173 (2-hydroxy-2-methyl-1-phenyl-propan-1-one, manufactured by Ciba Japan K.K.), and 2 parts by weight of the (C) component anisoin N-cyclohexyl carbamate (ANC-101, manufactured by Midori Kagaku Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Darocur 1173 (2-hydroxy-2-methyl-1-phenyl-propan-1-one, manufactured by Ciba Japan K.K.
  • ANC-101 anisoin N-cyclohexyl carbamate
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 2.
  • FIG. 7 is a graph of the polymerization conversion of photo-curable compositions (a-3 and b-9) as a function of time. The polymerization conversion was calculated from the peak intensity at 810 cm ⁇ 1 ascribed to the acryl group of HDODA.
  • FIG. 8 is a table of the half decay exposure of the peak intensity at 810 cm ⁇ 1 ascribed to the acryl group of HDODA.
  • a photo-curable composition (b-1) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 369 (manufactured by Ciba Japan K.K.), and no (C) sensitizer component.
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 1.
  • a photo-curable composition (b-2) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 369 (manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component 4-phenylglycine (manufactured by Tokyo Chemical Industry Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 369 manufactured by Ciba Japan K.K.
  • C 4-phenylglycine
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 1.
  • a photo-curable composition (b-3) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 369 (manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component 2-butoxyethyl 4-(dimethylamino)benzoate (manufactured by Tokyo Chemical Industry Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 369 manufactured by Ciba Japan K.K.
  • C 2-butoxyethyl 4-(dimethylamino)benzoate
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 1.
  • a photo-curable composition (b-4) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 369 (manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component dibenzylamine (manufactured by Tokyo Chemical Industry Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 369 manufactured by Ciba Japan K.K.
  • C component dibenzylamine
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 1.
  • a photo-curable composition (b-5) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 369 (manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component 2-mercaptobenzoxazole (manufactured by Tokyo Chemical Industry Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 369 manufactured by Ciba Japan K.K.
  • C 2-mercaptobenzoxazole
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 1.
  • a photo-curable composition (b-6) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 369 (manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component 2-mercaptobenzothiazole (manufactured by Tokyo Chemical Industry Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 369 manufactured by Ciba Japan K.K.
  • C 2-mercaptobenzothiazole
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 1.
  • the photo-curable composition according to Example 1 had a higher polymerization rate and a higher polymerization conversion than the compositions according to Comparative Examples 1 to 6.
  • the photo-curable composition according to Example 1 had a lower half decay exposure than the compositions according to Comparative Examples 1 to 6, thus achieving a patterning method having a higher throughput than before.
  • a photo-curable composition (b-7) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 651 (manufactured by Ciba Japan K.K.), and no (C) sensitizer component.
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 2.
  • a photo-curable composition (b-8) was prepared from 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 0.1 parts by weight of the (B) component Irgacure 651 (manufactured by Ciba Japan K.K.), and 0.5 parts by weight of the (C) component 2-mercaptobenzoxazole (manufactured by Tokyo Chemical Industry Co., Ltd.).
  • HDODA 1,6-hexanediol diacrylate
  • Irgacure 651 manufactured by Ciba Japan K.K.
  • C 2-mercaptobenzoxazole
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 2.
  • the photo-curable composition according to Example 2 had a polymerization rate equal to or higher than the polymerization rate of the compositions according to Comparative Examples 7 and 8 and a higher polymerization conversion than the compositions according to Comparative Examples 7 and 8.
  • the photo-curable composition according to Example 2 had a lower half decay exposure than the compositions according to Comparative Examples 7 and 8, thus achieving a patterning method having a higher throughput than before.
  • a photo-curable composition (b-9) was prepared from a mixed solution of 100 parts by weight of the (A) component 1,6-hexanediol diacrylate (HDODA, manufactured by Osaka Organic Chemical Industry Ltd.), 3 parts by weight of the (B) component Darocur 1173 (manufactured by Ciba Japan K.K.), and no (C) sensitizer component.
  • HDODA 1,6-hexanediol diacrylate
  • B Darocur 1173
  • the polymerization rate, the polymerization conversion, and the half decay exposure were measured in the same manner as in Example 2.
  • the photo-curable composition according to Example 3 had a higher polymerization rate and a higher polymerization conversion than the composition according to Comparative Example 9. As shown in FIG. 8 , the photo-curable composition according to Example 3 had a lower half decay exposure than the compositions according to Comparative Example 9, thus achieving a patterning method having a higher throughput than before.
  • the quartz glass was removed from the photo-cured product.
  • the quartz glass was easily removed from the photo-cured product.
  • the photo-cured product had a pattern corresponding to the surface profile of the quartz glass.
  • the present invention provides a photo-curable composition that can be easily cured.
  • the present invention also provides a high-throughput UV imprint method.

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EP2788389A4 (en) 2015-07-22
KR20140113694A (ko) 2014-09-24
EP2788389B1 (en) 2019-04-17
JP6108765B2 (ja) 2017-04-05
CN104039836B (zh) 2016-10-05
US11119406B2 (en) 2021-09-14
EP2788389A1 (en) 2014-10-15
US20180339444A1 (en) 2018-11-29
JP2013147635A (ja) 2013-08-01
CN104039836A (zh) 2014-09-10

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