Pattern forming method, pattern forming apparatus, and method for manufacturing semiconductor device

According to one embodiment, a pattern forming method using a template containing a pattern that has at least one recess section or protrusion section to transfer the shape of the pattern to a resin layer on a substrate, is provided. The method includes a process for coating the resin on the substrate, a process for making the hardness of the first portion as a portion of the resin higher than the hardness of the second portion as the portion other than the first portion, and a process in which the portion other than the pattern of the template makes contact with the first portion, in a state where a gap is maintained between the template and the resin, the shape of the pattern is transferred to the second portion, and the resin is cured. Embodiments of an apparatus for pattern forming are also provided.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2012-034461, filed Feb. 20, 2012; the entire contents of which are incorporated herein by reference.

FIELD

Embodiments described herein relate to the pattern forming method, the pattern forming apparatus, and the method for the manufacture of the semiconductor device.

BACKGROUND

In recent years, a method for the formation of the microfine patterns on wafers or other substrates by using a method called the imprint method has been used. In this method, a template having a micro-fine three-dimensional embossed pattern of protrusions and recesses is prepared on the surface of the template, and the embossed pattern of the template is pressed into a resin layer such as a or other pattern transferring material formed on the substrate. After the resist materials are cured in this state, the template is removed. In this way, in the surface of the resist, a three-dimensional reverse pattern of the embossed pattern of protrusions and recesses on the template is transferred into the resist material.

In such a pattern forming method, during the contacting of the pattern of the template with the resist material on the substrate, it is important to maintain an accurate spacing between the template and the substrate in order to accurately transfer the embossed pattern of the template into the resist material.

DETAILED DESCRIPTION

In general, one embodiment will be explained on the basis of figures in the following.

The figures are schematic or conceptual ones. The relationship between the thickness and the width of various parts and the ratio of sizes between the parts and so on are not restricted to be necessarily the same as the actual ones. Furthermore, even in the case of representing the same part, there may be cases in which the mutual dimensions or ratios are represented differently according to the diagrams.

Furthermore, in the present application specification document and various diagrams, the same symbols are attached to the same major elements as those described previously in regard to the diagrams that have already appeared, and a detailed explanation will be omitted appropriately.

According to the embodiment, during the contacting of the pattern of the template on the resin on the substrate, there is provided a pattern forming method capable of maintaining an accurate gap between the template and the substrate, a pattern forming apparatus, and a method for the manufacture of a semiconductor device.

The pattern forming method related to the embodiment, is a pattern forming method by using a template containing a pattern that has at least a protrusion and a recess being a reverse, or negative, three dimensional pattern of the pattern to be transferred into the resin layer on a substrate, is provided with a process for coating the resist on the substrate, a process for having the hardness of the first portion as a portion of the resist higher than the hardness of the second portion as the portion other than the first portion, and a process in which the portion other than the pattern of the template makes contact with the first portion, the contact thereof useful for maintaining a gap between the pattern transferring portion of the template and the substrate, the shape of the pattern is transferred to the second portion, and the resist is cured.

FIG. 1is a flow chart exemplifying the pattern forming method related to the first embodiment.

The pattern forming method related to the present embodiment is an imprint method by using a template containing a three-dimensional pattern that has at least one depressed section and a protruded section, which is transferred onto a resin on a substrate to provide a negative (reversed) three-dimensional pattern on the substrate.

First of all, as represented by the step S101, the resin is coated on the substrate. The resin, for example, is a photo-setting type resin, but a thermosetting type resin can also be used. In the present embodiment, the case of using the photo-setting type resin will be exemplified.

The resin is coated uniformly on the substrate. The resin is coated uniformly on the substrate by spin coating, for example.

Next, as represented by the step S102, the hardness of portions of the resin is adjusted. In other words, the hardness of the resin is adjusted so that the hardness of a first portion of the resin is greater than the hardness of a second portion of the resin.

Next, as represented by the step S103, the template pattern transfer is carried out on the second portion of the resin. Portions of the template that do not contain a pattern to be transferred may make contact with the first portion of the resin during this step. The contact between the template and the first portion of the resin may be used to gauge spacing between the template and the substrate such that a gap may be maintained to provide a desired spacing between the template and the substrate. In other words, the portion other than the pattern of the template makes contact with the first portion of the resin, in a state maintaining a gap between the template and the substrate in order to accurately transfer the shape of the pattern at a desired depth to the second portion of the resin, and then the second portion of the resin is cured.

In the pattern forming method related to the present embodiment in this manner, during positioning of the template to the substrate and the contact with the first portion of the resin, the first portion of the resin is utilized as a stop for the template. When contact between the template and the first portion of the resin is realized, the template may not be further pressed toward the substrate, and the template may remain in contact with, or be spaced away from, the first portion of the resin to regulate a gap between the template and the substrate. In doing so, during the transfer of the shape of the pattern to the resin, the gap between the template and the substrate, and particularly, the depth of the embossed pattern of the template, is set accurately.

Next, an explanation will be given in regard to the template for use in the pattern forming method related to the present embodiment.

FIG. 2AandFIG. 2Bare schematic diagrams exemplifying the constitution of the template for use in the pattern forming method related to the present embodiment.

FIG. 2Ais a schematic planar diagram of the template;FIG. 2Bis a schematic cross-sectional diagram of the line A-A shown inFIG. 2A.

As represented byFIG. 2AandFIG. 2B, a template110is provided with a base10and a pattern20is provided on the main surface10aof the base10. In the base10, for example, quartz for the transmission of ultraviolet rays therethrough is used as the material of the base10. In the case in which light transmission is not required, a metal, a semiconductor, an insulation material or other materials can also be used.

Protrusions21(first protrusions) projecting from the main surface10aas the pattern20are provided in the template110. On the main surface10a, for example, multiple first protrusions21, having recesses resulting therebetween, are provided to define a pattern region on the main surface10a. The shape of the protrusions21is determined by the shape (for example, a circular column shape, a line shape or the like) that is formed based on the desired reverse of the shape of the pattern to be formed on a substrate.

Furthermore, on the main surface10aof the base10, in the portion outside the region for the formation of the pattern20, projections30(second protrusions) are provided. The projections30are provided so that, for example, they surround the pattern20in one embodiment.

The projections30may also be provided by division into multiple locations of the main surface10a. In the case of division into multiple locations, the projections30can be provided in at least three locations on a nonlinear line.

The contacting end of the projections30is flat, for example. The cross-sectional shape of the contacting end of the second projections30may also be semispherical.

As represented byFIG. 2B, the height h2of the projections30from the main surface10ais provided uniformly. In the case of the provision of the projections30at multiple locations, the height h2of the projections30at various locations is provided uniformly.

The height h2of the projections30is lower than the height h1from the main surface10aof the first protrusions21. The difference Δh between the height h1and the height h2is the depth of the resulting recess formed by the transfer of the shape of the pattern20into the resin.

In such a template110, any of at least the pattern20(the first protrusions21) and the projections30may also be provided in one unit with the base10. Furthermore, the base10, the pattern20and the projections30may also be provided respectively as separate units.

FIG. 3AandFIG. 3Bare schematic diagrams showing a modified example of the template.

FIG. 3Ais a schematic planar diagram of the template, andFIG. 3Bis a schematic cross-sectional diagram of the line B-B shown inFIG. 3A.

As represented byFIG. 3AandFIG. 3B, the template111, in the same manner as the template110represented byFIG. 2AandFIG. 2B, is provided with the base10and the pattern20provided on the main surface10aof the base10. On the other hand, in the template111, the arrangement of the projections30is different from that for the template110. In the template111, the projections30provided on the main surface10aof the base10have outside projections (first projection30a) provided so that they surround the region for the formation of the pattern20and inside projections (second projections30b) provided in the inside of the region for the formation of the pattern20.

The first projections30amay also be provided by division into multiple locations of the main surface10a. In the case of division into multiple locations, the first projections30acan be provided in at least three locations on a nonlinear line. Furthermore, the second projections30bmay also be provided in a continuous form (frame form). Furthermore, the second projection30bmay also be provided by division into multiple locations of the main surface10a. In this embodiment, the template111comprises multiple pattern regions comprising the protrusions21in locations adjacent the first projections30aand second projections30b.

In the template111, in the same manner as the template110, any of at least the pattern20, the projections30aand the projections30bmay also be provided in one unit with the base10. Furthermore, the base10, the pattern20, the projections30aand the projections30bmay also be provided respectively as separate units.

FIG. 4AandFIG. 4Bare schematic diagrams showing another modified example of the template.

FIG. 4Ais a schematic planar diagram of the template, andFIG. 4Bis a schematic cross-sectional diagram along the line C-C shown inFIG. 4A.

As represented byFIG. 4AandFIG. 4B, the template112, in the same manner as the template110represented byFIG. 2AandFIG. 2B, is provided with the base10and the pattern20provided on the main surface10aof the base10. On the other hand, in the template112, the arrangement of the projections30is different from that for the template110.

In the template112, the projections30provided on the main surface10aof the base10have the inside projections30bprovided in the inside of the region for the formation of the pattern20. In other words, the projections30in the template112have the second projections30bonly. For example, the second projections30bmay be provided in a frame form. Furthermore, the second projections30bmay also be provided by division into multiple locations of the main surface10a.

In the template112, in the same manner as the template110and the template111, any of at least the pattern20and the projections30bmay also be provided in one unit with the base10. Furthermore, the base10, the pattern20, and the projections30bmay also be provided respectively as separate units.

Next, the specific example of the pattern forming method will be explained.

FIG. 5AtoFIG. 6Care schematic cross-sectional diagrams showing a specific example of the pattern forming method.

InFIG. 5AtoFIG. 6C, an example for the manufacture of the semiconductor device300(shown inFIG. 6C) by the pattern forming method related to the present embodiment is given.

In this specific example of the pattern forming method, the template110shown inFIG. 2AandFIG. 2Bwill be used.

First of all, as shown inFIG. 5A, a substrate60is loaded on a stage220. As the substrate60, for example, a semiconductor substrate (a silicon wafer or the like) is used. The substrate60may also be a material formed by the provision of a semiconductor layer on an insulation substrate. On the substrate60, a transistor or other elements may also be formed.

Next, a resin70is coated on top of the substrate60. As the resin70, a photo-setting type resin or a thermosetting type resin can be used. The resin70can be discharged toward the substrate60from a nozzle N, for example. The resin70is provided at a uniform thickness on the substrate60by spin coating or the like. The thickness of the resin70is, for example, 50 nanometers (nm).

Next, as shown inFIG. 5B, the resin70layer is semi-cured. Here, the cured state of the resin70can be represented by, for example, a curing ratio. The curing ratio is a value representing the progression of the curing. A curing ratio of 100% is a state beyond which no curing proceeds, and a curing ratio of 0% for a state in which no curing has occurred. The semi-curing of the resin70refers to the fact that the curing ratio of the resin70is, for example, in the range of more than 25% and less than 75%, for example, more than 40% and less than 60%.

In the case in which the resin70is a photo-setting resin, a first light C1is irradiated on the overall resin70. For example, for the ultraviolet light irradiation-setting type resin, the ultraviolet light is irradiated as the first light C1. The ultraviolet light is discharged from a high pressure mercury lamp or a laser light source.

In the case in which the resin70is a thermosetting resin or a photo-setting and thermosetting resin, it can also be brought to a semi-cured state in the same manner by heating.

Next, as shown inFIG. 5C, the hardness of the first portion71of the resin70is brought to be higher than the second portion72of the resin. Here, the curing ratio of the first portion71of the resin70is brought to more than 25% and less than 75%, for example, more than 40% and less than 60%. In one aspect, the curing ratio of the first portion71is 100% (complete curing) while the curing ratio of the second portion72is less than 100%.

In the case in which the resin70is a photo-setting resin, a second light C2is irradiated only on the first portion71of the resin70to provide the additional curing thereof. The second light C2may have an intensity that is greater than the intensity of the first light C1. The second light C2may be a light beam separate from the first light C1, or may be the same intensity of the first light C1for a longer time period. For example, for the ultraviolet light irradiation-setting type resin, the ultraviolet light is irradiated as the first light C1while the second portion72is shielded from the first light C1by a mask or covering, or by control of the direction and position of the light from the first light source C1. In this embodiment, the ultraviolet light may be provided by a high pressure mercury lamp or a laser light source.

In the case in which the resin70is a thermosetting resin or a photo-setting and thermosetting resin, it is also acceptable that only the first portion71is cured by partial heating.

Here, the first portion71is located such that, during the placing of the template110on top of the resin70, the second protrusions30of the template110at least partially overlap with, so as to be brought into contact with, the first portion71of the resin70and thus enable limitation of the movement of the template in the direction of the underlying substrate. The first portion71can be continuous or divided into multiple discrete locations. By this curing treatment, the entire thickness of the first portion71of the resin70is cured to a desired hardness relative to the hardness of the second portion72of the resin70.

By the treatments ofFIG. 5BandFIG. 5C, the hardness of the first portion71of the resin70is greater than the hardness of the second portion72. For the treatments ofFIG. 5BandFIG. 5C, it is also acceptable that the curing of the first portion71is carried out first as shown inFIG. 5C, then the semi-curing of the resin70is carried out as shown inFIG. 5B.

Next, as shown inFIG. 6A, the template110is placed over top of the resin70, and the protrusions21of the pattern20makes contact with the resin70. At this time, if the gap between the template110and the substrate60is gradually decreased, the front end side30aof the protrusions30of the template110will make contact with the top side71aof the first portion71of the resin70. At this contacting position, the gap between the template110and the substrate60is set. In other words, with the first portion71functioning as a stop for the extension of the template110toward the substrate60, the gap or spacing between the template110and the substrate60is set accurately.

During the step of pressing the template110into the resin70, The second portion72of the resin70is in a semi-cured state. Furthermore, since the height h1(refer toFIG. 2B) of the first protrusions21of the pattern20of the template110is higher than the height h2(refer toFIG. 2B) of the projections30, only the difference Δh (refer toFIG. 2B) extends into the second portion72of the resin70. Furthermore, in the state of the contacting of the projections30with the top side71aof the first portion71, the gap between the main surface10aand the surface72aof the second portion72is set. This gap is equivalent to the height h2of the projections30.

In this way, the first portion71of the resin70is the stop and the gap between the template110and the substrate60can be set accurately. Therefore, the pattern20of the template110does not contact the substrate60. Furthermore, the template110is arranged virtually parallel to the substrate60because the resin layer70is uniform in thickness, and thus each of the first portions71forming the stop have the same height. Since the template110is accurately arranged to engage the first portions71of the resin layer70, the protrusions21of the pattern20enter the second portion72of the resin70at a desired depth.

Here, it is also acceptable that the template110makes contact with the resin70when pressing of the template110is carried out, and the opposing force exerted on the template110is measured. In other words, if the projections30of the template110and the first portion71of the resin70make contact, the opposing force is exerted from the projections30with respect to the pressing force on the template110. It is also acceptable that this opposing force is measured and, in the case in which the measured opposing force reaches a preset value, the pressing is stopped.

The measurement of this opposing force can also be carried out at multiple locations in the plane along the main surface10a. By the measurement of the opposing force at multiple locations, a balance is ascertained in the plane of the pressing force of the template110. Furthermore, it is also acceptable to adjust the balance of pressure in the plane of the pressing force of the template110on the basis of the measured value of the opposing force at multiple locations. For example, it is also acceptable to adjust the pressing force of the template110so that it is uniform in the plane or to make the adjustment so that a constant pressure differential is provided in the plane in the pressing force which will ensure that the template is stopped against the first portions71across the entire surface of the substrate, and thus lays flat against the underlying substrate60.

Next, as shown inFIG. 6B, the template110is subjected to mold releasing from the resin70. In doing so, in the second portion72of the resin70, a pattern of depressions or recesses p1extend inwardly from the surface of the cured resin layer70as a negative, or reverse three dimensional pattern of the protrusions21of the pattern20on the template110. Since the second portion72is in a semi-cured state, the shape of the pattern of depressions p1is maintained even if the template110is subjected to mold releasing. In other words, the semi-cured hardness of the second portion72of the resin70hardness (the curing ratio) may be required for maintaining the shape of the pattern of depressions p1during mold releasing. Furthermore, in placing the template110on top of the resin70, since the gap between the main surface10aand the surface72aof the second portion72has been provided, during the mold releasing of the template110, no force above what is required to press the template into the semi cured second portion72of the resin layer70is exerted on the template110in the opposite direction to remove the template110from the resin layer70. By removing the template110from the resin70while the second portion72of the resin70remains in the semi-cured state, the breaking or damaging of the pattern of depressions p1during the mold releasing of the template110on top of the resin70is suppressed.

Next, as shown inFIG. 6C, after the template110is removed from the resin layer70, the treatment for the curing of the resin70as a whole is carried out. Here, the curing is completed to the curing ratio of 100%. In the case in which the resin70is a photo-setting type resin, a third light C3is irradiated on the overall resin70. For example, for an ultraviolet light irradiation-setting type resin, the ultraviolet light is irradiated as the third light C3. The irradiation energy (intensity) of the third light C3may be greater than the irradiation energy (intensity) of the first light C1during the semi-curing of the resin70. In the case in which the first portion71of the resin70has been completely cured, with this final curing treatment, only the second portion72is further cured.

In the case in which the resin70is a thermosetting resin or a photo- and thermosetting resin, by the heating of the overall resin70, the resin70is completely cured.

By the complete curing of the resin70, a transfer pattern P formed by the reversion of the shape of the pattern20in the resin70is formed. As a portion of the manufacturing process for the formation of this transfer pattern P, the semiconductor device300is manufactured. The transfer pattern P is used as a portion of the semiconductor device300, for example. Furthermore, the transfer pattern P is used as a mask during the etching of an underlying base material, then removed afterwards.

By such a pattern forming method, the gap between the template110and the substrate60is set accurately in the imprint method. In doing so, during the contacting of the template110with the resin70, the contacting of the pattern20of the template110and the substrate60is prevented. Furthermore, the input amount (depth) of the protrusions21into the resin70is stabilized and equalized across the surface of the substrate and the field (area of the resin layer70over which the recesses p1area provided). Therefore, the reversed transfer pattern P (the three dimensional reverse or negative of the pattern of recesses and protrusions of the template110) is formed accurately in the resin70layer. Furthermore, since the first portion71of the resin70is used as a stop of the template110, it is unnecessary to provide a stop on another part of the pattern forming apparatus, and the stop height is precisely aligned with the height of the resin70layer.

In the pattern forming method described above, as shown inFIG. 6B, after the mold releasing of the template110from the resin70, the curing of the resin70as a whole is carried out as shown inFIG. 6C. However, it is also acceptable that, as shown inFIG. 6A, in the state in which contact of the template110with the resin70occurs, the curing of the resin70as a whole is carried out without the mold releasing of the template110and, after the curing of the resin70, the template110is mold-released from the resin70.

Furthermore, in the pattern forming method described above, the second portion72of the resin70is brought to the semi-cured state in the process shown inFIG. 5B. However, it is also acceptable that, with the second portion72not cured as such, only the first portion71is, for example, completely cured with the process as shown inFIG. 5C, then the subsequent process is carried out. In this case, with the process as shown inFIG. 6A, in the state in which contact of the template110with the resin70occurs, the resin70as a whole is subjected to curing without the mold releasing of the template110. It is acceptable that the template110is mold-released from the resin70after the curing. Additionally, because a gap is also present between the exposed outer surface of the resin70layer and the base of the template110in the regions of the template110between each of the projections21, the surface area of contact between the template110surface and the resin70are reduced, resulting in less overall adhesion between the template110surface sand the resin, and thus a lower overall force needed to remove the template from the resin70, both where the resin is cured after template100removal, or before the template110is removed, as compared to full penetration of the template110into the resin70layer.

FIG. 7AandFIG. 7Bare schematic diagrams for exemplification in regard to multiple transfer regions.

FIG. 7Ais the whole planar diagram, andFIG. 7Bis the enlarged diagram of the section B inFIG. 7A.

As shown inFIG. 7A, in the case of the provision of multiple transfer regions R in one substrate60, the transfer of the pattern with one template110is repeated in sequence in regard to the multiple transfer regions R. Each transfer region R may comprise one or more die or device regions of the die or devices to be formed on the substrate60. As shown inFIG. 7B, the resin70coated on the transfer regions R has a first portion71and a second portion72. The first portion71is provided in the region outside the region of the formation of the transfer pattern P. The second portion72is provided in the region of the formation of the transfer pattern P. In regard to the process (refer to the step S102,FIG. 5BandFIG. 5C) for the adjustment of the hardness of the resin70, the hardness adjustment process is carried out before the contacting of the template110with the resin70.

It is also acceptable that the process for the adjustment of the hardness of the resin70is carried out before the contacting of the template110in regard to the respective multiple transfer regions R. It is also acceptable that the hardness of the resin70is adjusted at the same time in at least two of the multiple transfer regions R. In other words, it is also acceptable that, after the simultaneous adjustment of the hardness of the resin70of all multiple transfer regions R, the formation of the transfer pattern P with the template110is carried out in sequence in regard to the respective various transfer regions R. To reduce the quantity of resin, and thus underlying substrate area, used by the first portions71, the portions of the first portion71adjacent to an adjacent transfer region may be used in both transfer regions to form a portion of the stop for the template110in that region.

In the pattern forming method described above, the method for the formation of the transfer pattern P has been exemplified by using the template110. However, the same effect is seen when using the templates111and112(FIGS. 3A and 4A).

Furthermore, in addition to the materials like the templates110,111and112having the projections30in the base10, it is also acceptable to use a template having no projections30. In this case, it is also acceptable that, where the thickness of the resin70layer, and thus the thickness of the first regions71, are greater than the length or span of the protrusions21from the base10of the template, a portion of the main surface10aof the base10and the second portion72are allowed to make contact, the transfer of the pattern20is carried out, and a mold releasing agent is coated on the main surface10aof the base10. In doing so, during the mold releasing of the template from the resin70, the adherence force between the main surface10aand the resin70is decreased, and the destruction of the template, the breaking and damaging of the resin70and so on are suppressed.

FIG. 8is a schematic diagram exemplifying the pattern forming apparatus related to the second embodiment.

As shown inFIG. 8, the pattern forming apparatus200related to the second embodiment is an imprint apparatus by using a pattern20containing a template110having a three-dimensional pattern that has at least one depression and protrusion for transferring a reversed image of the three-dimensional pattern20in the resin70on the substrate60.

The pattern forming apparatus200is provided with a holding section210, a stage220, a pressing section230, a measuring section240, and a control section250.

The holding section210is for holding the template110. The holding section210, for example, adsorbs and holds the side opposite to the pattern20of the base10of the template110by vacuum.

The stage220is for the fixation of the substrate60at a desired position relative to the template, i.e., to align the substrate60and template110The resin70is coated on top of the substrate60. It is also acceptable that the coating section280containing the nozzle N for coating the resin70is provided in the pattern forming apparatus200.

The pressing section230is for carrying out the pressing of the pattern20into the resin70by moving either the holding section210or the stage220toward each other. A driving mechanism (not shown in the diagram) is provided in the holding section210or the stage220for facilitating this movement. The pressing section230moves at least the holding section210or the stage220with the driving mechanism to vary the gap between the two.

The measuring section240is for the measurement of the opposing force during the contacting of the template110with the resin70. The measuring section240includes a sensor241. The sensor241is provided on, for example, the side opposite to the side holding the template110of the holding section210. The sensor241, for example, is a load cell. With this sensor241, the opposing force is detected during the contacting of the template110with the resin70. The measuring section240receives the detected value sent from the sensor241, and sends a signal representative thereof to the control section250.

The control section250is for controlling the pressing force of the pattern20onto the resin70by the pressing section230according to the opposing force measured with the measuring section240. The control section250carries out the control to stop the pressing of the template110by the pressing section230, for example, when the opposing force measured with the measuring section240meets a preset threshold value.

FIG. 9is a diagram exemplifying the relationship between time and the opposing force measured with the measuring section240.

The abscissa shown inFIG. 9represents the time T of the pressing of the template110on the resin70, and the ordinate represents the opposing force F received by the template110.

In this embodiment, in the case of contacting of the template110with the resin70, with the first portion71of the resin70as the stop, the gap between the template110and the substrate60is set. As shown inFIG. 9, the opposing force F is generated from the time of contact with the pattern20of the template110with the resin70, and the opposing force F increases drastically at the time of contacting of the template110with the first portion71of the resin70.

At the location where this opposing force F increases drastically, the threshold value fthis provided. The control section250renders the indication of the pressure to the pressing section230, and determines whether or not the opposing force F measured with the measuring section240exceeds the threshold value fth. The control section250, in the case of the opposing force F exceeding the threshold value fth(time te), renders the indication to stop the pressing to the pressing section230. In doing so, the contacting of the template110with the first portion71of the resin70is accurately determined.

The curing section260has the function of curing the resin70. The curing section260may be configured to cure only the first portion71of the resin70. Furthermore, the curing section260may be configured to cure the resin70as a whole.

In the case of using a photo-setting resin as the resin70, the curing section260has a light source (not shown in the diagram) for the discharging of light for the curing of the resin70. As the light source for the partial curing of the first portion71, for example, a laser light source can be used. As a light source for the curing of the resin70as a whole, for example, a high pressure mercury lamp can be used.

In the case of using a thermosetting resin as the resin70, the curing section260has a heat source (not shown in the diagram) for heating the resin70for curing.

The pattern forming method as shown inFIG. 5AtoFIG. 6C, for example, can be carried out with the pattern forming apparatus200related to the present embodiment. In other words, with the pattern forming apparatus200related to the present embodiment, the pattern forming method as shown inFIG. 5AtoFIG. 6Cis carried out for the formation of the pattern. In doing so, the semiconductor device300containing a pattern or the like can be manufactured.

FIG. 10AtoFIG. 10Care schematic cross-sectional diagrams exemplifying the pattern forming method related to the third embodiment.

The pattern forming method related to the present embodiment is an imprint method that uses a template120having the pattern20including a plurality of recesses22extending inwardly of the base10of the template120.

This template120is provided with the base10, and the pattern20provided into the main surface10aof the base10. As the base10, for example, quartz for the transmission of ultraviolet light is used. On the main surface10a, for example, multiple recesses22are provided. The recesses22have a shape (a circular columnar shape, a line shape or the like) formed as a reverse three dimensional pattern of the three dimensional pattern to be formed in the resin70layer. In the template120, the region other than the region containing the recesses22for the formation of the pattern20is the main surface10a.

In the formation of the pattern using this template120, first of all, as shown inFIG. 10A, the substrate60is loaded on the stage220. As the substrate60, for example, a semiconductor substrate (a silicon wafer or the like) can be used. It is also acceptable that the substrate60is a material formed by the provision of a semiconductor layer on top of the insulation substrate. On the substrate60, a transistor or other elements may also be formed.

Next, the resin70is coated on top of the substrate60. As the resin70, for example, a photo-setting organic material can be used. The resin70is discharged from, for example, the nozzle N toward the substrate60. The resin70is provided at a uniform thickness on top of the substrate60by spin coating or the like. The thickness of the resin70is, for example, 50 (nm).

Next, the hardness of the first portion71of the resin70is made greater than the hardness of the second portion72. Here, the second portion72of the resin70is not cured. In one aspect, the curing rate of the first portion71is 100% (complete curing) while the curing rate of the second portion72is less than 100%.

In the case in which the resin70is a photo-setting type resin, light is irradiated on only the first portion71of the resin70(refer toFIG. 5C). In the case in which the resin70is a thermosetting type resin or a photo-setting and thermosetting type resin, the curing of only the first portion71by partial heating is also acceptable. The second portion72of the resin70is not cured as such.

Next, as shown inFIG. 10B, the template120is placed over the resin70, and the pattern20makes contact with the resin70. At this time, if the gap between the template120and the substrate60is gradually decreasing, a portion of the main surface10aother than the region of the template120for the formation of the pattern20will make contact with the first portion71of the resin70. At this contacting position, the gap between the template120and the substrate60is set. In other words, with the first portion71functioning as a stop, the gap between the template120and the substrate60is set accurately.

If the pattern20of the template120makes contact with the resin70, due to the surface tension of the resin70, the resin70enters the inside of the recesses22of the pattern20.

Next, in a state of contacting of the template120with the resin70, the treatment for the curing of the resin70as a whole is carried out. Here, the curing is complete curing (the curing ratio 100%). In the case in which the resin70is a photo-setting type resin, the third light C3is irradiated on the overall resin70via the template120. For example, for an ultraviolet light irradiation-setting type resin, the ultraviolet light is irradiated as the third light C3. Since the first portion71of the resin70has already been cured completely, with this treatment, only the second portion72is cured completely.

In the case in which the resin70is a thermosetting resin or a photo-setting and thermosetting resin, by the heating of the overall resin70, the resin70is completely cured.

After the completion of the curing of the overall resin70, as shown inFIG. 10C, the template120is mold released from the resin70. In doing so, in the second portion72of the resin70, the transfer pattern (PC) comprising a plurality of projections is formed as a reverse three dimensional image of the three dimensional pattern of the recesses22in the resin70layer.

As a portion of the manufacturing process for the formation of this transfer pattern PC, the semiconductor device300is manufactured. The transfer pattern PC can be used as a portion of the semiconductor device300, for example. Furthermore, the transfer pattern PC is used as a mask during the etching of a base material, then removed afterwards.

By such a pattern forming method, the gap between the template120and the substrate60is set accurately in the imprint method. In doing so, during the contacting of the template120with the resin70, the contacting of the pattern20of the template120and the substrate60is prevented. Furthermore, the amount of the resin70that enters the protruded sections (protrusions21) is stabilized. Therefore, the transfer pattern PC is formed accurately in the resin70.

As explained above, with the pattern forming method, the pattern forming apparatus and the method for the manufacture of the semiconductor device, in causing the contacting of the pattern of the template with the resin on the substrate, a precise gap between the template and the substrate can be maintained.

The present embodiments have been explained above. However, the present invention is not to be restricted to these examples. For example, with respect to the various embodiments described above, the materials formed by the conduction of the addition, elimination, or design changes constitutional elements, for appropriate, or the materials formed by the appropriate combination of characteristics of the various embodiments by those in the industry, as long as they maintain the gist of the present invention, are included in the scope of the present invention.