Etching characteristics of tin oxide thin films in argon–chlorine radio frequency plasmas

We have developed an etch process suitable for high resolution transparent conductive oxide patterning with high etch rates, up to 70 nm/min, and applicability to large area flat panel display substrates. It was found that the addition of small amounts of Cl2 significantly enhanced the etch rate compared to addition of pure argon but that beyond 25% Cl2 the rate tended to fall. There is a significant loading effect where the etch rate approximately doubled for exposed tin oxide areas between 80% and 10% of the substrate area. This loading sensitivity was found to increase with increasing power and decreasing Cl2 concentration. It was also observed that local changes in pattern dimensions affected the uniformity of the etch rate. A large photoresist etch rate was observed between one and three times that of the tin oxide and it decreased as the area of photoresist coverage increased. Linewidth loss, up to 4 μm at high powers, was overcome using improved ultraviolet exposure, leading to feature resolution capabilities of <5 μm. Etch rate inhomogeneity was also observed on a local scale, possibly due to redeposition of sputtered photoresist. Overetching, however, ensures rapid clearing of tin oxide islands without damage to the underlying SiO2 buffer layer.