##STR00001##
wherein R1 is a C3-8 branched or cyclic alkyl group, and R2 is a C1-8 straight-chain, branched or cyclic alkyl group, is effective as a photoacid generator when used in a photoresist material for light of 300 nm or less.
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0. 1. A diazodisulfone compound of the formula:
##STR00024##
wherein R1 is a branched or cyclic alkyl group having 3 to 8 carbon atoms; and R2 is a straight-chain, branched or cyclic alkyl group having 1 to 8 carbon atoms.
0. 2. A diazodisulfone compound according to
0. 3. A diazodisulfone compound according to
bis(cyclohexylsulfonyl)diazomethane,
cyclohexylsulfonylethylsulfonyldiazomethane,
bis(isopropylsulfonyl)diazomethane,
bis(tert-butylsulfonyl)diazomethane,
bis(sec-butylsulfonyl)diazomethane,
tert-butylsulfonylmethylsulfonyldiazomethane,
tert-butylsulfonylcyclohexylsulfonyldiazomethane,
bis(cyclopentylsulfonyl)diazomethane,
cyclopentylsulfonyl-tert-butylsulfonyldiazomethane, or
bis(isoamylsulfonyl)diazomethane.
0. 4. A diazodisulfone compound of the formula:
##STR00025##
wherein R1 is a branched or cyclic alkyl group having 3 to 8 carbon atoms; and R2 is a branched or cyclic alkyl group having 3 to 8 carbon atoms.
0. 5. A compound according to
0. 6. A compound according to
wherein R1 is a branched alkyl group having 3 to 8 carbon atoms; and R2 is a cyclic alkyl group having 3 to 8 carbon atoms.
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This application is a continuation of application Ser. No. 646,909 filed Jan. 28, 1991 now abandoned.
wherein R1 is as defined above, is reacted with methylene chloride in an organic solvent in the presence of a base to yield the compound of the formula:
R1SCH2SR1 (III)
wherein R1 is as defined above.
As the base, there can be used NaOH, KOH, NaH, sodium methoxide, sodium ethoxide, pyridine, piperidine, morpholine, triethylamine, N-methylpyrrolidine,
As the organic solvent, there can be used alcohols such as methanol, ethanol, propanol, isopropenol, etc.; aromatic hydrocarbons such as benzene, toluene, etc.; cyclic ethers such as 1,4-dioxane, tetrahydrofuran (THF), etc.
Methylene chloride is used usually in an amount of 1 to 20 moles, preferably 5 to 15 moles, per mole of the compound of the formula (I).
The reaction is carried out usually at 20° to 100° C., preferably at 25° to 65° C. for usually 1 to 20 hours, preferably 2 to 10 hours.
The resulting compound of the formula (III) is purified by a conventional method.
The compound of the formula (III) is, then, reacted with hydrogen peroxide in a solvent in the presence of a catalyst to yield the compound of the formula:
R1SO2CH2SO2R1 (IV)
wherein R1 is as defined above.
The hydrogen peroxide is used usually in an amount of 1 to 10 moles, preferably 2 to 6 moles, per mole of the compound of the formula (III).
As the catalyst, there can be used sodium tungstate, ammonium phosphomolibdate, etc.
As the solvent, there can be used water; alcohols such as methanol, ethanol, propanol, isopropanol, etc.; a mixed solvent of water and an alcohol, etc.
The reaction is carried out usually at 0° to 100° C., preferably at 20° to 80° C., for usually 1 to 20 hours, preferably 1 to 10 hours.
The resulting compound of the formula (IV) is purified by a conventional method.
Then, the compound of the formula (IV) is reacted with tosyl azide in a solvent in the presence of a base to yield the compound of the formula:
##STR00005##
wherein R1 is as defined above.
The tosyl azide is used usually in an amount of 0.5 to 5 moles, preferably 0.5 to 2 moles, per mole of the compound of the formula (IV).
As the base, there can be used NaOH, KOH, NaH, sodium methoxide, sodium ethoxide, pyridine, piperidine, morpholine, triethylamine, N-methylpyrrolidine, etc.
As the solvent, there can be used water; water-soluble organic solvents such as methanol, ethanol, propanol, isopropanol, acetone, 1,4-dioxane, etc.; and a mixed solvent of water and a water-soluble organic solvent.
The reaction is carried out usually at 0° to 50° C., preferably at 5° to 30° C., for usually 1 to 20 hours, preferably 1 to 10 hours.
The resulting compound of the formula (V) is purified by a conventional method.
When R1 and R2 are different, the compound of the formula (I) can be synthesized easily by the following reaction scheme (2): ##STR00006##
This is explained in detail as follows.
The compound of the formula (II) in an amount of 1 mole is mixed with usually 0.5 to 10 moles, preferably 0.5 to 2 moles of paraformaldehyde (e.g. n=3), followed by introduction of HCl gas in an amount of equimolar or mole of the paraformaldehyde at usually 10° C. or lower, preferably −10° to +5° C. Then, anhydrous calcium chloride is added to the resulting mixture to carry out the reaction at usually 10° C. or lower, preferably −10° to +5° C., for usually 1 to 20 hours, preferably 1 to 10 hours, followed by purification by a conventional method to yield the compound of the formula:
R1SCH2Cl (VI)
wherein R1 is as defined above.
The compound of the formula (VI) is then reacted with the compound of the formula:
R2SH (VII)
wherein R2 is as defined above but different from R1, in a solvent in the presence of a base to yield the compound of the formula:
R1SCH2SR2 (VIII)
The compound of the formula (VI) is used in an amount of usually 0.5 to 5 moles, preferably 0.5 to 2 moles, per mole of the compound of the formula
As the base, there can be used NaOH, KOH, NaH, sodium methoxide, sodium ethoxide, etc.
As the solvent, there can be used alcohols such as methanol, ethanol, isopropanol, etc.
The reaction is carried out usually at 0° to 50° C., preferably at 0° to 20° C., for usually 1 to 20 hours, preferably 1 to 10 hours.
The resulting compound of the formula (VIII) is purified by a conventional method.
The compound of the formula (VIII) is oxidized with hydrogen peroxide, followed by diazotization with tosylazide, in the same manner as described in the reaction scheme (1) to yield the compound of the formula (I).
The compound of the formula (VIII) can also be synthesized by the following reaction scheme (3): ##STR00007##
This is explained in detail as follows.
The compound of the formula (II) is reacted with the compound of the formula (VII) and methylene chloride in a solvent in the presence of a base to yield the compound of the formula (VIII).
The compound of the formula (VII) is used usually in an amount of 0.5 to 5 moles, preferably 0.5 to 2 moles, per mole of the compound of the formula (II), and methylene chloride is used usually in an amount of 1 to 20 moles, preferably 5 to 15 moles, per mole of the compound of the formula (II).
As the base, there can be used NaOH, KOH, NaH, sodium methxoide, sodium ethoxide, pyridine, piperidine, morpholine, triethylamine, N-methylpyrrolidine, etc.
As the solvent, there can be used alcohols such as methanol, ethanol, propanol, isopropanol, etc.; aromatic hydrocarbons such as benzene, toluene, etc.; cyclic ethers such as 1,4-dioxane, tetrahydrofuran, etc.
The reaction is carried out usually at 20° to 100° C., preferably 25° to 65° C. for usually 1 to 20 hours, preferably 2 to 10 hours.
The resulting product is purified by a conventional method such as distillation, column chromatography, etc. to yield the compound of the formula (VIII).
The compound of the formula (VIII) is converted to the compound of the formula (I) in the same manner as described in the reaction scheme (2).
When R1 and R2 are different, the reaction scheme (2) is preferable from the viewpoint of practical production.
The compound of the formula (I) is effectively used in a chemical amplified resist material wherein there is used a polymer having a property of alkali-soluble by the action of an acid. When the resist material is exposed to KrF excimer laser light or the like, the compound of the formula (I) present in the exposed portion generates an acid by the following reaction scheme (4): ##STR00008##
When heat treatment is applied after the exposure step, functional groups of the polymer in the resist material is subjected to a chemical change by the acid to become alkali-soluble by the following reaction scheme (5):
##STR00009##
The resulting alkali-soluble polymer is released into an alkali developing solution at the time of development.
On the other hand, since non-exposed portions do not generate an acid, no chemical change takes place even if heat treated to produce no alkali-soluble groups. Further, since the compound of the formula (I) has a dissolution inhibiting effect, the non-exposed portions become difficultly soluble in the alkali developing solution.
As mentioned above, when pattern formation is carried out by using a chemical amplified resist material containing the compound of the formula (I), a large difference in solubility in the alkali developing solution takes place between the exposed portions and the non-exposed portions. As a result, there can be formed a positive tone pattern having good contrast. Further, as is clear from the reaction scheme (5), since the acid generated by exposure to light acts catalytically, not only the necessary amount of acid can be produced by the exposure to light, but also the light exposure energy amount can be reduced.
Needless to say, the compound of the formula (I) is useful for producing semiconductors and can be used as a photosensitive reagent in the field of applying photo reaction such as photograving, printing plate materials, etc.
The present invention is illustrated by way of the following Examples.
(1) Free radical polymerization of p-tert-butoxystyrene
A solution of p-tert-butoxystyrene (17.6 g) in toluene containing catalytic amount of 2,2′-azobisisobutyronitrile (AIBN) was heated at 80° C. for 6 hours under nitrogen. After cooling, the reaction mixture was poured into methanol and the polymer was precipitated. The polymer was filtered, washed with methanol and dried under reduced pressure to afford 15. 5 g of poly(p-tert-butoxystyrene) as white powders.
A solution of poly(p-tert-butoxystyrene) (15.0 g) obtained in above (1) and hydrochloric acid (10 ml) in 1,4-dioxane was refluxed for 1.5 hours with stirring. The mixture was cooled, poured into water and the white solid was precipitated. The polymer was filtered, washed and dried under reduced pressure to afford 11.8 g of the title compound as white powders having
After dissolving sodium azide (22.5 g, 0.35 mole) in a small amount of H2O, the resulting solution was diluted with a 90% ethanol aqueous solution (130 ml). To this, an ethanol solution dissolving p-toluenesulfonyl chloride (60 g, 0.32 mole) was added dropwise at 10-25° C., followed by reaction at room temperature for 2.5 hours. The reaction solution was concentrated at room temperature under reduced pressure. The resulting oily residue was washed with H2O several times and dried over anhydrous MgSO4. After removing the drying agent by filtration, there was obtained 50.7 g of the title compound as a colorless oil.
1HNMR δ ppm (CDCl3): 2.43 (3H, s, CH3), 7.24 (2H, d, J=8Hz, Ar 3-H, 5-H), 7.67 (2H, d, J=8Hz, Ar 2-H, 6-H).
IR (Neat) νcm−1: 2120 (—N3).
To cyclohexylthiol (20.2 g, 0.17 mole), an ethanol solution dissolving potassium hydroxide (12.0 g, 0.21 mole) was added dropwise at room temperature and mixture was stirred at 30°±5° C. for 30 minutes. Then methylene chloride (18.2 g, 2.14 mole) was added to this mixture and reacted with stirring at 50°±5° C. for 6 hours. After standing at room temperature overnight, the reaction mixture was diluted with ethanol (55 ml) and added with sodium tungstate (0.4 g). Then, 30% hydrogen peroxide (50 g, 0.44 mole) was added dropwise to this solution at 45°-50° C., reacted with stirring for 4 hours at the same temperature, then added with H2O (200 ml) and standed overnight at room temperature. The precipitate was filtered, washed with H2O and dried. The resultant solid was recrystallized from ethanol to give 15.5 g of bis(cyclohexylsulfonyl)methane as white needles.
mp. 137°-139° C.
1HNMR δ ppm (CDCl3) 1.13-2.24 (20H, m, cyclohexylic CH2×10), 3.52-3.66 (2H, m, cyclohexylic CH×2), 4.39 (2H, s, CH2).
IR (KBr-disk) ν cm−1: 1320, 1305.
To a solution of sodium hydroxide (1.7 g) in a 60% ethanol aqueous solution (70 ml), bis(cyclohexylsulfonyl)methane (12.1 g, 0.04 mole) obtained in above (1) was added, then an ethanol solution of p-toluenesulfonyl azide (8.2 g, 0.04 mole) obtained in Reference Example 2 was added dropwise at 5°-10° C., followed by the reaction at room temperature for 7 hours. After standing at room temperature overnight, the precipitate was filtered, washed with ethanol and dried. The resultant solid was recrystallized from acetonitrile to give 8.0 g of bis(cyclohexylsulfonyl)diazomethane as pale yellow prisms.
mp. 130°-131° C.
1HNMR δ ppm (CDCl3): 1.13-2.25 (20H, m, cyclohexylic CH2×10), 3.36-3.52 (2H, m, cyclohexylic CH2).
IR (KBr-disk) ν cm−1: 2130 (CH2), 1340, 1320.
Ultraviolet spectrophotometric characteristics of bis(cyclohexylsulfonyl)diazomethane in acetonitrile solution was shown in FIG. 1. It is clear that bis(cyclohexylsulfonyl)diazomethane of the present invention shows good transmittance between 240 and 300 nm.
To a mixture of cyclohexylthiol (20.2 g, 0.17 mole) and 80% paraformaldehyde (6.5 g, 0.17 mole), dry hydrogen chloride was introduced at −8°−0° C., then anhydrous calcium chloride was added and stirring was violently continued at 0° C. for 3 hours. After removing the precipitate by filtration, the filtrate was distilled under reduced pressure to afford 16.5 g of chloromethylcyclohexylsuflide as a colorless oil having a boiling point of 100°-103° C./14 mmHg.
To ethanethiol (5.7 g, 0.09 mole), an ethanol solution dissolving potassium hydroxide (6 g, 0.09 mole) was added dropwise at room temperature and mixture was stirred for 15 minutes. Then chroromethylcyclohexylsulfide (15 g, 0.09 mole) obtained in above (1) was added dropwise to this mixture at 10°±5° C. and reacted with stirring at that temperature for 3 hours. After standing at room temperature overnight, the reaction mixture was diluted with ethanol (30 ml) and H2O (30 ml) and added with sodium tungstate (0.3 g). Then, 30% hydrogen peroxide (53 g, 0.47 mole) was added dropwise to this solution at 45°-50° C., followed by reaction for 6 hours at the same temperature, then added with H2O (300 ml) and standed overnight at room temperature. The precipitate was filtered, washed with H2O and dried. The resultant solid (19 g) was recrystallized from ethanol to give 15.5 g of cyclohexylsulfonylethylsulfonylmethane as white needles.
mp: 89°-91° C.
1HNMR δ ppm (CDCl3): 1.13-2.24 (13H, m, cyclohexylic CH2×5 and CH2CH3), 3.44 (2H, q, J=7.3Hz, CH2CH3), 3.53-3.68 (1H, m, cyclohexylic CH), 4.40 (2H, s, CH2).
IR (KBr-disk) ν cm−1: 1315.
To a solution of sodium hydroxide (1.7 g) in a 60% ethanol aqueous solution (70 ml), cyclohexylsulfonylethylsulfonylmethane (10.2 g, 0.04 mole) obtained in above (2) was added. Then an ethanol solution of p-toluenesulfonyl azide (8.2 g, 0.04 mole) obtained in Reference Example 2 was added dropwise at 5°-10° C., followed by reaction at room temperature for 7 hours. After standing at room temperature overnight, the reaction mixture was extracted with ethyl acetate (25 ml×3), the organic layer was separated, washed with H2O and dried over anhydrous MgSO4. After removing the drying agent by filtration, the solvent was evaporated in vacuo, the resultant residue (12 g) was subjected to column separation [silica gel, Wakogel C-200, a trade name, manufactured by wako Pure Chemical Industries, Ltd.; eluent, n-hexane/ethyl acetate/methylene cloride=8/1/0→7/1/1(v/v)]to give 4.1 g of cyclohexylsulfonylethylsulfonyldiazomethane as pale yellow crystals.
m.p.: 85°-86.5° C.
1HNMR δ ppm (CDCl3): 1.13-2.27 (13H, m, cyclohexylic CH2×5 and CH2CH3), 3.38-3.54 (3H, m, cyclohexylic CH and CH2CH3).
IR (KBr-disk) ν cm−1: 2120 (CH2), 1325.
Using various thiol compounds of the formula (II) as a starting material, the syntheses were carried out in the same manner as described in Example 1 to give the corresponding bis(alkylsulfonyl)diazomethane. The results are summarized in Table 1.
TABLE 1
Appearance
1HNMR δ ppm
Example
R1
(purification)
m.p.
(CDCl3)
IR (KBr)
3
##STR00010##
pale yellow needles (recrystallization from methanol)
82˜84° C.
1.46(12H, d, J=7Hz,
##STR00011##
2120 cm−1
3.74(2H, m, J=7Hz,
##STR00012##
1340 cm−1 1320 cm−1
4
##STR00013##
pale yellow needles (recrystallization from ethanol)
121˜121.5° C.
1.52(18H, s, CH3 × 6)
2120 cm−1 1330 cm−1 1315 cm−1
5
##STR00014##
pale yellow oil (column separation: silica gel, wako Gel C-200; eluent, n-hexane/ethyl acetate = 20/1)
—
1.14(12H, d, J=7Hz,
##STR00015##
2120 cm−1
2.37(2H, m,
##STR00016##
3.38(4H, d, J=7Hz,
##STR00017##
1350 cm−1 1330 cm−1
Using various thiol compounds of the formula (II) and of the formula (VII) severally as a straight material, the syntheses were carried out in the same manner as described in Example 2 to give the corresponding diazomethane derivatives. The results are summarized in Table 2.
TABLE 2
Appearance
1HNMR δ ppm
Example
R1
R2
(purification)
m.p.
(CDCl3)
IR (KBr)
6
##STR00018##
CH3—
pale yellow needles (recrystallization from ethanol)
90.5˜92° C.
1.51(9H, s, —C(CH3)3) 3.39(3H, s, —SO2CH3)
2120 cm−11335 cm−1 1310 cm−1
7
##STR00019##
##STR00020##
pale yellow needles (recrystallization from n-hexane/ ethyl ether)
86˜88° C.
1.13-2.27(19H, m,
##STR00021##
2120 cm−1
3.47-3.63(1H, m,
##STR00022##
1330 cm−1 1315 cm−1
Using various thiol compounds having a straight-chain alkyl group as a starting material, the syntheses were carried out in the same manner as described in Example 1 to afford the corresponding bis(alkylsulfonyl)diazomethane. The results are summarized in Table 3.
TABLE 3
##STR00023##
Comparative
Appearance
1HNMR δ ppm
Example
R
(purification)
m.p.
(CDCl3)
IR
1
C2H5—
pale yellow needles
88.7˜89.7° C.
1.46(6H, t, J=7.3Hz,
2140 cm−1
(recrystallization
—CH2CH3 × 2)
from methanol)
3.48(4H, q, J=7.3Hz,
1335 cm−1
—CH2CH3 × 2)
2
CH3(CH2)3—
pale yellow needles
44˜47° C.
0.98(6H, t, J=7Hz,
2145 cm−1
(column separation:
—CH3 × 2)
silica gel,
1.42-1.56(4H, m,
Wakogel C-200;
—CH2CH3 × 2)
eluent, n-hexane/
1.79-1.90(4H,
1350 cm−1
ethyl acetate =
—SO2CH2CH2 × 2)
20/1)
3.38(4H, d, J=7Hz,
1335 cm−1
—SO2CH2CH2— × 2)
3
CH3(CH2)7—
pale yellow oil
—
0.82-1.94(30H, m
2120 cm−1
(column separation:
CH3(CH2)6— × 2)
silica gel,
3.43(4H, t,
1340 cm−1
Wakogel C-200;
—SO2CH2— × 2)
eluent, n-hexane/
ethyl acetate = 3/1
COMPARATIVE EXAMPLE 4
To a solution of methyl methylsulfinylmethylsulfide (7.0 g, 0.06 mole) and sodium tungsate (0.14 g) in methanol (40 ml) and H2O (4 ml), 30% hydrogen peroxide (21 g, 0.19 mole) was added dropwise at 45°-50° C., then reacted with stirring under reflux for 8 hours and standed at room temperature overnight. The reaction solution was poured into H2O (400 ml), and the precipitate was filtered, washed with H2O and dried. The resultant solid (9.5 g) was recrystallized from ethanol to effort 7.8 g of bis(methylsulfonyl)methane as white leaflets.
m.p.: 148°-149.5° C.
1HNMR δ ppm (CDCl3): 3.26 (6H, s, CH3×2), 4.43 (2H, s, CH2)
IR (KBr-disk) ν cm−1: 1310.
Using bis(methylsulfonyl)methane (7.5 g, 0.04 mole) obtained in above (1), the reaction was carried out in the same manner as described in Example 1, (2), and the crude solid (4.5 g) was chromatographed on silica gel (Wakogel C-200) with n-hexane/ethyl acetate (8/1 → 4/1 → 3/1) as eluent to give 2.5 g of bis(methylsulfonyl)diazomethane as white crystals.
m.p.: 120°-124° C.
1HNMR δ ppm (CDCl3): 3.37 (6H, s, CH3×2).
IR (KBr-disk) ν cm−1: 2145 (CN2), 1335, 1320.
A resist material having the following composition was prepared:
Poly(p-tert-butoxystyrene-p-
6.0
g
hydroxystyrene)
[Polymer obtained in Reference
Example 1, (2)]
Bis(cyclohexylsulfonyl)diazomethane
0.3
g
[Photoacid generator obtained in
Example 1, (2)]
Diethylene glycol dimethyl ether
13.7
g
Using the resist material, a pattern was formed as shown in FIG. 2. That is, the resist material was spin coated on a substrate 1 such as a 6 inch silicon wafer in diameter and prebaked by a hot plate at 90° C. for 90 seconds to give a resist material film 2 of 1.0 μm thick [
Resist materials were prepared in the same manner as described in Application Example 1 except for using the diazodisulfone compounds obtained in Examples 2 to 7 as the photoacid generator. Patterns were formed on semiconductor substrates in the same manner as described in Application Example 1. The results are shown in Table 4.
TABLE 4
Exposure
energy
Application
Photoacid
amount
Resolution
Example No.
generator
(mJ/cm2)
(μm L/S)
2
Example 3
25
0.3
3
Example 4
25
0.3
4
Example 5
30
0.3
5
Example 2
30
0.3
6
Example 6
30
0.3
7
Example 7
25
0.3
As is clear from Table 4, good positive tone patterns are formed by using the resist materials containing the compound of the formula (I) as the photoacid generator.
Resist materials were prepared in the same manner as described in Application Example 1 except for using the bis(straight-chain alkylsulfonyl)diazomethanes obtained in Comparative Examples 1 to 4. Using the resist materials, patterns were tried to form on semiconductor substrates in the same manner as described in Application Example 1, but no positive tone patterns were formed, since non-exposed portions were dissolved at the time of development.
These results show that the compounds of the formula (I) of the present invention obtained by introducing a bulky alkyl group into at least one of R1 and R2 moisties of the formula (I) play an important role to exhibit dissolution inhibiting effect for the alkali developing solution.
As mentioned above, when the photosensitive resist materials containing the diazodisulfone compounds of the formula (I) of the present invention are used for a light source of 300 nm or less such as deep UV light, KrF excimer laser light (248.4 nm), etc., fine patterns with good shapes of submicron order can easily be obtained.
The compound of the formula (I) of the present invention exhibits remarkable effects as the photoacid generator when exposed to not only deep UV light, KrF excimer laser light, but also ArF excimer laser light, electron beams, and X-rays.
Urano, Fumiyoshi, Nakahata, Masaaki, Fujie, Hirotoshi, Oono, Keiji
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