U.S. patent application number 14/289581 was filed with the patent office on 2014-09-18 for copper-filled trench contact for transistor performance improvement.
The applicant listed for this patent is Chris Auth, Mark Bohr, Kelin J. Kuhn, Kaizad Mistry. Invention is credited to Chris Auth, Mark Bohr, Kelin J. Kuhn, Kaizad Mistry.
Application Number | 20140264879 14/289581 |
Document ID | / |
Family ID | 38748779 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140264879 |
Kind Code |
A1 |
Kuhn; Kelin J. ; et
al. |
September 18, 2014 |
COPPER-FILLED TRENCH CONTACT FOR TRANSISTOR PERFORMANCE
IMPROVEMENT
Abstract
Methods of fabricating a first contact to a semiconductor
device, which fundamentally comprises providing a semiconductor
device formed on a substrate. The substrate further includes a
conductive surface. A dielectric layer is formed over the substrate
and has an opening exposing the conductive surface. The opening
extends an entire length of the semiconductor device, partway down
the entire length of the device, extending from the device onto
adjacent field of the device, or and a combination thereof. A
barrier layer is formed within the opening. A copper containing
material fills the opening to form a first contact to the
semiconductor device.
Inventors: |
Kuhn; Kelin J.; (Aloha,
OR) ; Mistry; Kaizad; (Lake Oswego, OR) ;
Bohr; Mark; (Aloha, OR) ; Auth; Chris;
(Portland, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kuhn; Kelin J.
Mistry; Kaizad
Bohr; Mark
Auth; Chris |
Aloha
Lake Oswego
Aloha
Portland |
OR
OR
OR
OR |
US
US
US
US |
|
|
Family ID: |
38748779 |
Appl. No.: |
14/289581 |
Filed: |
May 28, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13569150 |
Aug 7, 2012 |
8766372 |
|
|
14289581 |
|
|
|
|
11396201 |
May 23, 2006 |
8258057 |
|
|
13569150 |
|
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Current U.S.
Class: |
257/754 ;
438/655 |
Current CPC
Class: |
H01L 29/41725 20130101;
H01L 23/5226 20130101; H01L 2924/0002 20130101; H01L 21/76856
20130101; H01L 29/78 20130101; H01L 2924/0002 20130101; H01L
21/76843 20130101; H01L 21/76859 20130101; H01L 29/66477 20130101;
H01L 21/76874 20130101; H01L 2924/00 20130101; H01L 29/456
20130101; H01L 23/485 20130101 |
Class at
Publication: |
257/754 ;
438/655 |
International
Class: |
H01L 29/45 20060101
H01L029/45 |
Claims
1. A semiconductor device comprising: a semiconductor substrate
having a contact region; a dielectric layer on a top surface of the
semiconductor substrate having an opening exposing at least a
portion of the contact region; a conductive material in the opening
forming a contact to the contact region; and a via connector on a
portion of the first contact and on a portion of the dielectric
layer.
2. The semiconductor device of claim 1, further comprising a
metallization layer connected to the via connector.
3. The semiconductor device of claim 2, wherein the metallization
layer is over the entire via connector.
4. The semiconductor device of claim 1, wherein the opening has an
opening length and an opening width wherein the opening length is
greater than the opening width.
5. The semiconductor device of claim 4, wherein the opening length
extends one of an entire length of the contact region, partially
across the entire length of the contact region, or from the contact
region onto an adjacent field of the contact region.
6. The semiconductor device of claim 1, wherein the contact region
is a conductive surface on the semiconductor substrate.
7. The semiconductor device of claim 6, wherein the contact region
is formed of a silicide material.
8. The semiconductor device of claim 6, wherein the contact region
is a doped region of the semiconductor substrate.
9. The semiconductor device of claim 1, wherein the conductive
material comprises copper.
10. The semiconductor device of claim 1, further comprising a
barrier layer lining surfaces of the opening, the barrier layer
comprising copper silicide.
11. A method of forming a semiconductor device, comprising: forming
a contact region on a semiconductor substrate; forming a dielectric
layer on a top surface of the semiconductor substrate; forming an
opening in the dielectric layer exposing at least a portion of the
contact region; filling the opening with a conductive material to
form a first contact to the semiconductor device; and forming a via
connector on a portion of the first contact and on a portion of the
dielectric layer.
12. The method of claim 11, wherein forming the via connector
comprises a dual damascene process.
13. The method of claim 12, wherein the first contact and the via
connector are filled simultaneously with the conductive
material.
14. The method of claim 11, wherein the conductive material is
copper.
15. The method of claim 11, further comprising forming a
metallization layer on a top surface of the via connector.
16. The method of claim 15, wherein forming the metallization layer
and the via connector comprises a dual damascene process.
17. The method of claim 11, further comprising forming a barrier
layer within the opening, wherein the barrier layer performs as a
silicide layer, a diffusion barrier for copper, and a nucleation
layer for copper.
18. The method of claim 17, further comprising forming a copper
containing material on the barrier layer within the opening.
19. The method of claim 11, wherein filling the opening comprises
an electroless deposition process.
20. The method of claim 19, further comprising performing a surface
treatment to produce an activated surface.
Description
RELATED APPLICATIONS
[0001] The present application is a Continuation of U.S. patent
application Ser. No. 13/569,150, filed on Aug. 7, 2012, which is a
Divisional of U.S. patent application Ser. No. 11/396,201, filed on
Mar. 30, 2006, Issued as U.S. Pat. No. 8,258,057 on Sep. 4,
2012.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the present invention relate to the
fabrication of interconnect structures in microelectronic devices.
In particular, embodiments of the present invention relate to
utilizing copper to form contact immediately to device formed on a
semiconductor substrate.
[0004] 2. State of the Art
[0005] The fabrication of microelectronic devices involves forming
electronic components on microelectronic substrates, such as
silicon wafers. These electronic components may include
transistors, resistors, capacitors, and the like, with intermediate
and overlying metallization patterns at varying levels, separated
by dielectric materials, which interconnect the electrical
components to form integrated circuits. The metallization patterns
are generally referred to as "interconnects."
[0006] One of the main issues confronting the semiconductor
processing industry is that of the resistance problem in
metallization layers. An industry-wide effort has undertaken to
address the problem. Since the beginning, the semiconductor
processing industry has relied on aluminum and aluminum alloys to
serve as metallization layers. Silicon dioxide was selected as the
insulator of choice although polyimide, a polymer, was used in a
number of products by IBM for a number of years. With each
succeeding generation of technology, the resistance problem grows.
Because each generation requires that the dimensions of the
semiconductor structure be reduced, the minimum line-space
combination must also decrease. As the line-space combination
decreases, the resistance of the semiconductor structure
increases.
[0007] Copper metallurgy has been proposed as a substitute for
aluminum metallurgy as a material for the metallization layers
since copper exhibits greater conductivity than aluminum. Yet
several problems have been encountered in the development of copper
metallurgy. The main issue is the fast diffusion of copper through
an insulator, such as silicon dioxide, to form an undesired copper
oxide compound. Another issue is the known junction-poisoning
effect of copper. These issues have led to the development of a
liner to separate the copper metallization layer from the
insulator.
[0008] Suitable liners include titanium nitride, tantalum nitride,
tungsten silicon nitride, zirconium, hafnium, titanium, tantalum,
and the like.
[0009] FIG. 1A illustrates a conventional semiconductor structure
100 (e.g., a transistor). The semiconductor structure 100 includes
a substrate 102 having formed therein isolation regions (Shallow
Junction Isolation, STI) 104. Active or passive devices can be
formed on the substrate 102. Such devices typically include source
and drain regions 106, gate dielectric 112, gate electrode 114,
spacers 110 and silicide surfaces 108 and 116. As shown in FIG. 1B,
to electrically connect to and from the device, contacts 120 (first
contacts) are made to the device. Typically, several layers of
interconnections are also made to connect to the first layer of
contacts. An interlayer dielectric layer 118 is formed and
patterned on the substrate 102. Through vias (or contact holes) are
formed in the dielectric layer 118 to expose contact areas on the
substrate. Contact areas typically are source/drain regions and/or
on top of the gate electrode 114. To establish/enhance the contact
connection, silicide layers 108 and 116 are formed on the surface
of these regions as shown in FIGS. 1A-1B. The through vias are then
filled with tungsten (referred to as tungsten plug) to form the
first level of contact to the device. In some applications, an
additionally contact 122 (or VIAO) formed in a dielectric layer 124
is also formed to connect the contact or tungsten plug 120. The
additional contact (or VIAO) 122 can be filled with copper. Then, a
plurality of metallization layer 130 having dielectric material 126
and conductive lines 128 are formed on top of the device.
[0010] Because of the undesirable characteristics of copper, copper
has not been used in forming the first contact that is immediate to
the device. However, as devices are scaled smaller and smaller, the
high resistivity characteristic of the conductive material such as
tungsten that is typically used in the first contact layer is
becoming more undesirable. Tungsten causes parasitic resistance in
the device by introducing high resistivity and low conductivity at
the first contact level, at the junction from the first contact
level to other interconnection levels in the devices. Thus, there
is a need for a first layer of contact directly to the device that
will lower resistivity overall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] While the specification concludes with claims particularly
pointing out and distinctly claiming that which is regarded as the
present invention, the advantages of this invention can be more
readily ascertained from the following description of the invention
when read in conjunction with the accompanying drawings in
which:
[0012] FIG. 1A-1B illustrates a conventional semiconductor device
such as a transistor;
[0013] FIG. 2 illustrates an exemplary semiconductor device made
according to embodiments of the present invention where a first
contact to the device is formed with copper;
[0014] FIGS. 3A-1-3A-3 illustrates a top view of a first contacts
made to source/drains regions for the device shown in FIG. 2;
[0015] FIG. 3B-1 illustrates a three-dimensional view of a first
contacts made to a source/drains region for a conventional
device;
[0016] FIG. 3B-2 illustrates a three-dimensional view of a row of
first contact pillars made to a source/drain region for a
conventional device;
[0017] FIG. 3C illustrates a three-dimensional view of a first
contacts made to a source/drains region for a device according to
embodiments of the present invention;
[0018] FIGS. 4A-4C illustrate an exemplary process flow of making a
semiconductor device made according to embodiments of the present
invention where a first contact to the device is formed with
copper;
[0019] FIGS. 5A-5C illustrate another exemplary process flow of
making a semiconductor device made according to embodiments of the
present invention where a first contact to the device is formed
with copper;
[0020] FIGS. 6A-6E illustrate yet another exemplary process flow of
making a semiconductor device made according to embodiments of the
present invention where a first contact to the device is formed
with copper and where there is no prior silicide;
[0021] FIGS. 7-9 illustrate exemplary methods of making a
semiconductor device made according to embodiments of the present
invention where a first contact to the device is formed with copper
with FIG. 7 illustrating a method where no silicide is used, FIG. 8
illustrating a method with silicide being used and FIG. 9 with
silicide being forming through a contact opening.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT
[0022] In the following detailed description, reference is made to
the accompanying drawings that show, by way of illustration,
specific embodiments in which the invention may be practiced. These
embodiments are described in sufficient detail to enable those
skilled in the art to practice the invention. Certain known
processes are not described or discussed in details in order to not
obscure the invention. It is to be understood that the various
embodiments of the invention, although different, are not
necessarily mutually exclusive. For example, a particular feature,
structure, or characteristic described herein, in connection with
one embodiment, may be implemented within other embodiments without
departing from the spirit and scope of the invention. In addition,
it is to be understood that the location or arrangement of
individual elements within each disclosed embodiment may be
modified without departing from the spirit and scope of the
invention. The following detailed description is, therefore, not to
be taken in a limiting sense, and the scope of the present
invention is defined only by the appended claims, appropriately
interpreted, along with the full range of equivalents to which the
claims are entitled. In the drawings, like numerals refer to the
same or similar functionality throughout the several views.
[0023] Embodiments of the present invention relate to the
fabrication of interconnect structures in microelectronic devices.
More particularly, embodiments of the present invention disclose
the use of copper (Cu) in the Front-End-Of-Line (FEOL) processing
for a semiconductor device such as a transistor. As is known, a
semiconductor device is typically formed buried in the
semiconductor substrate. What end up being exposed are usually
contact regions for interconnecting the devices to other
metallization layers. Minimizing resistance from one
interconnection level to the next is desired for an efficient and
optimal device.
[0024] Currently, copper is not used in the FEOL processing due to
the high tendency of copper to diffuse through an insulator even
though copper has the desirable low resistivity and high
conductivity characteristics. Copper can create copper oxide and
disrupt the device. Copper can also migrate into the substrate,
diffuse, and create both yield and reliability issues as it getters
on dislocations or other interfaces. Because of such dangerous
possibility, contacts immediately above the surface of the
semiconductor substrate or the device have been formed with
tungsten (W) to provide conductive interfaces or interconnection to
the device while preventing the diffusion of copper into the device
areas. Copper is used in many metal layers in the Back-End-Of-Line
processing (e.g., dual damascene processing) to form metallization
layers.
[0025] Fabrication of a semiconductor device includes two main
process flows, FEOL and BEOL processes. In the FEOL process, wafer
substrates are marked, STI regions are formed, e.g., by
implantation, P- and N-wells are formed, e.g., by implantation,
poly gate stacks are etched and formed, and source and drain
regions are also formed by doping. Also, silicide layers or regions
are also formed to enhance or establish conductive surfaces to the
device. Also in the FEOL process, the first contact level is made
to the device. The first contact levels typically include contacts
to the source/drain regions and the gate electrode region (or the
respective silicide surfaces). In the BEOL process, the device and
the associated contacts are interconnected to metallization layers
including forming the metallization and dielectric layers. Copper
has been used in the BEOL process, e.g., dual damascene processing
to form vias and trenches in the dielectric layers.
[0026] As mentioned, in conventional FEOL processing, tungsten is
used for the first layer of contact. Embodiments of the present
invention relate to forming the first layer of contact using
copper. Additionally, the conventional FEOL processing has the
first contacts being vertical thin lines (or pillars), referred to
as "round contacts." Embodiments of the present invention include
forming the first contacts with "extended interconnect-style
contacts" or "trench contacts" that have rectangular/square
configurations. In one embodiment, a first contact extends the
entire length of the contact region. In one embodiment, the first
contact extends the entire length of the contact region and replace
a a set of conventional contact pillars. For example, the first
contact to a source region would extend the entire length of the
source region. In other embodiments, the contact would extend only
partially down the length of the contact region.
[0027] Embodiments of the present invention also pertain to using
barrier layers to encapsulate the first contact that is made of
copper. Embodiments of the present invention also include forming a
silicide layer that can also act as a barrier layer and in some
embodiments, the silicide layer is a copper silicide layer.
Embodiments of the present invention also reduce contact resistance
from the first contact to the device, between the first contact and
the silicide layer, and between the first contact and other
metallization layer above the first contact.
[0028] Embodiments of the present invention may enable better
density scaling and cross-technology scaling by enabling optimal
placement and alignment flexibility in interconnection positioning.
Additionally, with the trench contact configuration, one device can
be connected to another without going up to another metallization
layer as is currently done in the art. More importantly, the copper
contacts provide reduction in parasitic resistance in the device by
eliminating the conventional copper-to-tungsten junction and
replacing it with copper-t-copper junction from the device to the
metallization layers. The resistivity reduction in the contacts and
interconnection also enable more conductivity, thus, better drive
current in a device. Furthermore, the extended interconnect-style
contact in the first contact level improves drive current by
enhancing not just vertical conductivity but also lateral
conductivity since the contact extend more laterally compared to a
conventional round-type contact. Thus, the conductivity to and from
the device is increased, and in many cases, an increase of 30-45%
drive current have been observed with devices made in according to
embodiments of the present invention.
[0029] FIG. 2 illustrates an exemplary microstructure device 200
fabricated according to embodiments of the present invention. The
device 200 can be a transistor or capacitor or other semiconductor
device. The device 200 is formed on a semiconductor substrate 202
(e.g., a silicon wafer). Isolation regions such as STI 204 are
formed in the substrate 202 to isolate one device from another as
is known in the art. Source and drain regions 206 are also formed
by doping into the substrate 202 as known in the art. Between the
source and drain regions 206 and on the top surface of the
substrate 202, a gate dielectric 210 is formed. A gate electrode
208 is formed on top of the gate dielectric 210. Contacts to the
device 200 can be made to the source and drain regions 206 and
optionally, the gate electrode 208. The source/drain regions or
gate electrode can sometimes be referred to as conductive surfaces
so that the first contact can be made to the device 200. Often, a
layer of silicide material 212 is formed over the source and drain
regions 206 and optionally, the gate electrode 208 to enhance the
contact. The silicide layer 212 can be formed as conventionally
done. When silicide layer 212 is include, the contact surfaces are
the silicide surfaces. Spacer sidewalls 218 are also disposed on
each side of the gate electrode 208.
[0030] Contacts are made to the device. As referred herein, the
first layer of contact refers to the contact that is made immediate
to the device 200 or on the top surface of the substrate 202 or as
illustrated in FIG. 2 (on top of the silicide layer 212). Thus,
contacts are made to the source/drain regions 206 and the gate
electrode 208 (or their respective silicide layer formed thereon).
In one embodiment, a dielectric layer 216 is formed on the top
surface of the substrate 202. Openings 201 are formed into the
dielectric layer 216 and expose the silicide layer 212. In one
embodiment, the silicide layer 212 lines the bottom of each opening
201. In one embodiment, a barrier layer 214 lines the entire
surface (bottom surface and sidewalls) of the opening 201 as shown
in FIG. 2. The openings 201 are then filled with copper to form the
first contact 220 using methods such as deposition, sputtering,
electroplating, or electroless plating. In one embodiment, a seed
layer (not shown) is also used to line the opening and on top of
the barrier layer 214 to promote the adhesion of the copper or to
promote nucleation of copper to form the first contact 220. In one
embodiment, a via connector 222 is formed that connects to the
first contact 220. In one embodiment, the via connector 222 and the
opening 201 are filled in a single operation. The via connector 222
is then interconnected to one or more metallization layers (MT1 to
MT8) 226 above. Methods such as dual damascene processing can be
used to form the via connector 222 and the metallization layers
MT1-MT8. Interlevel dielectric layers are also used at each
metallization layer as is known in the art.
[0031] In more particular, the terms wafer and substrate used in
the following description include any base semiconductor structure.
Both are to be understood as including silicon-on-sapphire (SOS)
technology, silicon-on-insulator (SOI) technology, thin film
transistor (TFT) technology, doped and undoped semiconductors,
epitaxial layers of silicon supported by a base semiconductor
structure, as well as other semiconductor structures well known to
one skilled in the art. Furthermore, when reference is made to a
wafer or substrate in the following description, previous process
steps may have been utilized to form regions/junctions in the base
semiconductor structure and layer formed above, and the terms wafer
or substrate include the underlying layers containing such
regions/junctions and layers that may have been formed above. The
following detailed description is, therefore, not to be taken in a
limiting sense, and the scope of the present invention is defined
only by the appended claims.
[0032] The silicide layer 212 can be formed using a conventional
method such as depositing a conductive material (e.g., using
chemical vapor deposition) on the top surface of the source/drain
regions 206 or the gate electrode 208 and then anneal the structure
to form the silicide material. In one embodiment, the silicide
layer 212 comprises any metal that is capable of reacting with
silicon to form metal silicide. Examples of such metals include Ti,
Ta, W, Co, Ni, Pt, Pd and alloys thereof. The silicide layer 212
may be deposited using a conventional deposition process including
chemical vapor deposition, physical vapor deposition, sputtering,
evaporation, chemical solution deposition, plating, and the like.
To complete the silicide layer formation, the structure is annealed
to convert the silicide metal layer 212 into a metal silicide. The
annealing is typically done at a temperature from about
600-3000.degree. C. An inert gas (e.g., helium, argon, and
nitrogen) may be presence during the silicide annealing.
[0033] The dielectric layer 216 includes a substance that comprises
a material selected from a group consisting of a polymer, a foamed
polymer, a fluorinated polymer, a fluorinated-foamed polymer, an
aerogel, and an insulator oxide compound. The polymer includes
polyimide. The insulator oxide compound may include silicon
dioxide, silicon nitride, carbon doped oxide, fluorinated silicon
oxide, boron/phosphorous doped oxide, and the like. The dielectric
layer 216 can be formed using a conventional method such as
chemical vapor deposition, evaporation, atomic layer deposition, or
chemical solution deposition.
[0034] Vias 201 may be formed into the dielectric layer 216 using
methods known in the art, e.g., etching, photolithography,
lithography, ion milling, laser ablation, damascene, dual
damascene, and the like. The vias 201 are opening formed in the
dielectric layer 216 and extending into the dielectric layer. In
one embodiment, the vias 201 have a trench-like configuration or an
extended interconnect-style configuration as opposed to the
conventional thin vertical line via.
[0035] The barrier layer 214 is formed to prevent diffusion of the
copper atoms into the dielectric layer 216. This diffusion changes
the microstructure of a portion of the device 200 and causes
undesired effects. The barrier layer 214 can be formed using
conventional methods. The barrier layer 214 can be thin and in one
embodiment, less than 100 .ANG.. In other embodiments, barrier
layer 214 is less than 20 .ANG., less than 15 .ANG., and even less
than 10 .ANG. along the sidewalls of the opening 201 and
optionally, along all surfaces of the opening 201. In one
embodiment, the barrier layer 214 is made of a material that can
both act as a diffusion barrier for the interconnect material (such
as acting as a diffusion barrier for copper and copper alloys) and
act as an activation/nucleation layer for the interconnect material
to form thereon (such as acting as a seed layer for the copper to
form).
[0036] Materials that can be used as a barrier layer include but
are not limited to ruthenium (Ru), paladium (Pd), rhodium (Rh),
nickel (Ni), cobalt (Co), and platinum (Pt), titanium (Ti),
tantalum (Ta), titanium nitride (TiN), TaN, WsiN, Zr, hafnium (Hf),
tungsten (W), etc. A portion of the barrier layer 214 may also
extend over and abut the surface of dielectric layer 216.
[0037] In one embodiment, a seed layer (not shown) is deposited on
the barrier layer 214 prior to the deposition of the copper to form
the first contact 220. A low-energy ion implantation can be used to
form the seed layer. In one embodiment, depositing the seed layer
includes depositing a copper seed layer. In one embodiment,
depositing the seed layer includes depositing copper seed layer
having a thickness of less than 100 Angstroms. This can be achieved
using an 8.times.10.sup.16 ion implantation of copper. In one
embodiment, the energy of implantation includes about 100
electron-volts. Additionally, the copper seed layer can also be
implanted at an angle normal to the planarized surface.
[0038] The seed material may be deposited in a chemical vapor
deposition (CVD) process, an atomic layer deposition (ALD) process
or a physical vapor deposition (PVD) process, such as magnetron
sputtering, but is not so limited. The seed material provides a
nucleation site for a subsequent electroless plating process for
the copper. The seed material may include, but is not limited to,
copper (Cu), palladium (Pd), cobalt (Co), nickel (Ni), ruthenium
(Ru), platinum (Pt), alloys thereof, and the like.
[0039] In one embodiment, copper is electrolessly deposited into
the via 201 to form the first contact 220. The electroless
deposition process may include any autocatalytic (e.g., no external
power supply is applied) deposition of the conductive material
layer through the interaction of a metal salt and a chemical
reducing agent. As is known in the art, preparing or treating a
surface, may be necessary in order to produce an activated surface
so that the surface that is receptive to the electroless deposition
process.
[0040] In one embodiment, during the electroless deposition, the
seed material serves as the activated surface upon which the
electroless deposition forms. The seed material also acts as a
region which controls the placement of the deposited copper from
the electroless deposition solution only deposits on the prepared
or treated surface (e.g., the seed material).
[0041] In one embodiment, the electroless plating bath or
deposition solution may comprise cobalt and alloys thereof (such as
cobalt alloyed with tungsten, boron, phosphorus, molybdenum, and/or
the like), nickel and alloys thereof (such as nickel alloyed with
tungsten, boron, phosphorus, molybdenum, and/or the like), copper,
palladium, silver, gold, platinum metals and their selective alloys
to fill narrow and high aspect ratio trenches and via holes. It is,
of course, understood that the electroless deposition solution may
also include additives (such as suppressors, polyethylene glycol,
and anti-suppressors, di-sulfide) and complexing agents (such as
thiosulfate and peroxodisulfate). Although a few examples of
materials that may comprise the electroless deposition solution are
described here, the solution may comprise other materials that
serve to deposit the conductive material electroles sly. The
technique of electroles sly depositing a metal or metal alloy is
known to those skilled in the art, and may be performed either by
immersing the substrate in an electroless deposition solution, by
semi-immersion, or by spraying the electroless deposition solution
onto the substrate or target (e.g., the dielectric material layer
216). It is well known to those skilled in the art that the seed
material may be subsumed during the electroless deposition process,
such that the seed material may become continuous with the
conductive material.
[0042] In one embodiment, the contact 220 is planarized after the
copper fills the vias 201, usually by a technique called chemical
mechanical polish (CMP) or by an etching process, which removes the
copper, which is not within the opening 201.
[0043] In one embodiment, via connector 222 are formed to
electrically interconnect to the first contact 220. A conventional
BEOL process can be used to form the via connector 222. For
example, a dual damascene method can be used to form the via
connector 222. The via connector 222 connects to the metallization
layers 226, which can also be formed using similar methods. In an
alternative embodiment, the copper deposited in the opening to form
the first contact 220 is etched or otherwise removed in a way to
leave the via connector 222 extending from the first contact 220.
In one embodiment, the first contact 220 and the via connector 222
are filled simultaneously with copper. It is to be noted that dual
damascene process is not the only technique that can be used to
form the first contact 220 and the via connector 222. Conventional
metal etching methods can be used to form the first contact 220 and
the via connector 222, sequentially or simultaneously.
[0044] FIGS. 3A-1 to 3A-3 describe in more details an exemplary
embodiment where the first contact has a configuration of an
extended interconnect-style contact as opposed to the conventional
round via or line of vias (in other words, a conventional vertical
pillar; or line of pillars) contact shown in FIG. 3B-1 and FIG.
3B-2. In the present embodiment (FIG. 3A-1), the first contact 220
extends an entire length of the source and drain regions 206.
Similarly, the first contact 220 that is formed over the gate
electrode 208 may also extend the entire length of the gate
electrode 208. It is to be understood that in many devices, the
first contact 220 does not extend the entire length of the source
and drain regions or that the first contact 220 extends a length
sufficient to allow electrical interconnection to the device (FIG.
3A-2). In one embodiment, the first contact 220 has a rectangular
configuration as shown in FIGS. 3A-1 to 3A-3.
[0045] FIG. 3A-1 illustrates the device 200 from a top view with
the source and drain regions 206 and the gate electrode 208
showing. The silicide layer 212 is not shown for clarity purpose.
In one embodiment, the opening 201 is formed so that the opening
201 extend an entire length L101 of the source/drain regions 206.
In one embodiment, the opening 201 extends an entire length of the
device. In other embodiments, the opening 201 extends down a
fraction of the device as shown in FIG. 3A-2. In yet other
embodiments, the opening 201 extends a fraction of the device and
then extend larger to meet the via connector 222 as shown in FIG.
3A-3. While FIGS. 3A-1 and 3A-2 show the top view of the device
FIG. 3A-3 shows the cross-sectional side view for clarity
purposes.
[0046] The via connector 222 needs not be placed entirely over the
first contact 220. As shown in FIGS. 3A-1 and 3A-2, the via
connector 222 is placed partially in contact with and only
partially over the first contact 220. Similarly, the first
metallization layer MT1 226 needs not be placed entirely over the
first contact 220 or the via connector 222. As shown in FIG. 3A-1,
the metallization layer MT1 226 is placed partially in contact with
and only partially over the via connector 222 and/or the first
contact 220.
[0047] FIG. 3B-1 illustrates the configuration of a conventional
via contact (e.g., device 100). Here, a source/drain region 106 and
a dielectric layer 118 formed over the source/drain region are
shown. The via has a configuration of a cylindrical tube (or
pillar) and as such, often is called "round contact." The
conventional via is typically only a thin vertical conductive line
forming through the dielectric layer and connecting to the contact
region (e.g., source/drain region) as shown in FIG. 3B-1. The
conventional via can be implemented as a single pillar (as in FIG.
3B-1) or a line of pillars (as in FIG. 3B-2) On the other hand, in
one embodiment, the first contact 220 made according to embodiments
of the present invention has the configuration of a rectangular
contact or trench contact as shown in FIG. 3C (in a three
dimensional view).
[0048] The extended configuration or trench contact configuration
for the first contact 220 enables flexibility in circuit design and
placement of the interconnecting elements. For example, the trench
contact need not run the entire length of the source drain region,
and (because of the high conductivity of the contact due the Cu
fill) can also extend significantly beyond the edge of the source
drain region. The via connector 222 needs not be placed directly
over the region of the substrate 202 where the device is formed
("field region") but instead, can be placed toward the side where
space is available and still able to interconnect to the first
contact 220. Additionally, filling the trench contact with copper
may be easier than filling a round via contact with copper.
Furthermore, the extended first contact filled with copper reduces
vertical resistivity as well as lateral resistivity; and, being
filled with copper, the first contact further optimizes drive
current by providing optimal vertical and lateral conductivity. In
one embodiment, a device built using the extended-interconnect
style first contact has a 10-15% conductivity improvement over the
conventional round style first contact.
[0049] FIGS. 4A-4C illustrate an exemplary process flow and
corresponding structures throughout the process of making a
semiconductor device 400 during a FEOL according to embodiments of
the present invention. A substrate 402 is provided. The substrate
402 has a set of isolation regions 404 formed therein. Source and
drain regions 406 are also formed in the substrate. A gate
dielectric 408 is formed on the top surface 410 of the substrate
402. A gate electrode 412 is formed on top of the gate dielectric
layer 408. Typically, the gate electrode 412 and the gate
dielectric are referred to as a gate stack. Spacers 414 are also
formed on each side of the gate stack.
[0050] In one embodiment, (FIGS. 4A-4B), a silicide layer is formed
over the contact regions of the device and in the present example,
a silicide layer 416 is formed over the source/drain regions 416
and the gate electrode 412. In one embodiment, to form the silicide
layer 416, a conductive metal is deposited and the structure is
annealed to convert the metal and the top portion of the substrate
into metal silicide. The silicide layer 416 is resistant to
etching, is conductive, and behaves like a semiconductor crystal.
The silicide layer 416 thus provides a conductive surface on a
silicon surface. A dielectric layer 418 is formed over the surface
410 and patterned to form opening 420 as shown in FIG. 4B. In one
embodiment, the opening 420 each extend the entire length of the
device 400. Alternatively, the opening 420 only extends down part
of the device. In either the case of a full extension or a partial
extension, the opening may extend beyond the device over the
adjacent field. For example, the opening 420 extends into the page
and covers the entire length of the device 400 that extends into
the page. An etch stop layer (not shown) may be used to prevent
etching or damaging to the silicide layer 416 during the opening
420 formation process.
[0051] Alternatively, the dielectric layer 418 is formed over the
substrate 402 (over the top surface 410) prior to the silicide
layer 416 formation. The dielectric layer 418 is then etched to
form the opening 420. Then, the silicide layer 416 is formed inside
each of the opening 420.
[0052] In FIG. 4C, a barrier layer 422 is formed and lined the
opening 420. In one embodiment, the barrier layer 422 (e.g., TaN)
is formed in conjunction with an oxygen plasma treatment applied to
the barrier layer 422 to improve its barrier performance.
[0053] Copper is then deposited into the opening 420 to form the
first contact 424. In one embodiment a seed layer is not used. In
such embodiment, the barrier layer 422 is made of a material that
is capable of being activated to be a nucleated site for the copper
to form thereon. In one embodiment, electroless plating is used to
deposit the copper. In another embodiment, electroplating is used
to deposit the copper. When the device 400 is completed, at this
point, the FEOL may be considered finished and the BEOL begins to
form other interconnection layers to the device 400. For example,
via connectors and metallization layers are formed to connect to
the first contact 424 using methods known in the art.
[0054] FIGS. 5A-5C illustrate an exemplary process flow similar to
FIGS. 4A-4C with the addition of a seed layer 506 (e.g., a copper
seed layer) being deposited on top of the barrier layer 422.
[0055] FIGS. 6A-6E illustrate another exemplary process flow of
making a semiconductor device 600 during a FEOL according to
embodiments of the present invention. A substrate 602 is provided.
The substrate 602 has a set of isolation regions 604 formed
therein. Source and drain regions 606 are also formed in the
substrate. A gate dielectric 608 is formed on the top surface 610
of the substrate 602. A gate electrode 612 is formed on top of the
gate dielectric layer 608. Typically, the gate electrode 612 and
the gate dielectric 608 are referred to as a gate stack. Spacers
614 are also formed on each side of the gate stack.
[0056] In one embodiment, (FIGS. 6A-6B), a dielectric layer 618 is
formed over the substrate 602 (over the top surface 610). At this
point, unlike the device 400, no silicide layer is formed. The
dielectric layer 618 is then etched to form the opening 620. In one
embodiment, the opening 620 each extend the entire length of the
device 600. Alternatively, the opening 620 only extends down part
of the device. In either the case of a full extension or partial
extension, the opening may extend beyond the device over the
adjacent field. For example, the opening 620 extends into the page
and covers the entire length of the device 600 that extends into
the page.
[0057] FIG. 6C, a barrier layer 622 is formed and lined the opening
620. In one embodiment, the barrier layer 622 is also formed to
provide an additional function much like that of a metal silicide
layer. The barrier layer 622 thus contains a metal or a conductive
material that will react with the silicon surface and form a
conductive surface similar to a conventional metal silicide.
Further, the barrier layer 622 is made of material that inhibits
diffusion of the copper into the dielectric layer 618. Examples of
such metal include TaN, TaN(O), WN, tantalum, cobalt, nickel, and
copper. In one embodiment, the barrier layer 622 (e.g., TaN or WN)
is formed in conjunction with an oxygen plasma treatment applied to
the barrier layer 622 to improve its barrier performance. The
barrier layer 622 is also subjected to annealing so that the metal
component in the barrier layer 622 can form metal silicide. It is
to be noted herein that only the portion of the barrier layer 622
that lies above the source/drain region or on top of a silicon
containing surface such as the source and drain region that a
silicide layer is formed. Specifically, a portion of the barrier
layer 622 is converted into silicide where the barrier layer 622
material is formed over the silicon. In one embodiment, copper is
deposited and immediately annealed to form copper silicide which
then allow the copper silicide to act as a barrier layer 622 with
conductivity characteristic that of a metal silicide. FIG. 6D
illustrates the bottom portion 622-B of the barrier layer 622
converting into a silicide portion after the barrier layer 622 is
treated. The barrier layer 622 thus has a portion 622-B that
transforms into a silicide layer in addition to the rest of the
barrier layer 622 being a diffusion barrier for copper.
[0058] FIG. 6E shows copper being deposited into the opening 620 to
form the first contact 624. In one embodiment a seed layer is not
used. In such embodiment, the barrier layer 622 is also made of a
material that is capable of being activated to be a nucleated site
for the copper to form thereon. In one embodiment, electroless
plating is used to deposit the copper. In another embodiment,
electroplating is used to deposit the copper. When the device 600
is completed, at this point, the FEOL may be considered finished
and the BEOL begins to form other interconnection layers to the
device 600. For example, via connector and metallization layers are
formed to connect to the first contact 624 using methods known in
the art. In an alternative embodiment, a copper seed layer is
deposited on top of the barrier layer 622 prior to the deposition
of the copper through electroplating or electroless plating.
[0059] FIG. 7 illustrates an exemplary method 700 of forming a
contact to a semiconductor device (e.g., during a FEOL process). At
702, a substrate having a contact device (e.g., a transistor)
formed thereon is provided. At 704, a dielectric layer is formed
immediately above the top surface of the semiconductor device. At
706, an opening (having a trench like configuration or a
rectangular configuration) is formed into the dielectric layer to
expose a contact region (e.g., source/drain region) immediately
above the top surface of the semiconductor device. The openings can
extend the entire length of the device, for example, the openings
exposing the source/drain regions extend the entire length of the
source/drain regions. Alternatively, the opening only extends down
part of the device. In either the case of a full extension or a
partial extension, the opening may extend beyond the device over
the adjacent field. At 708, the opening is lined with a barrier
layer such that the barrier liner covers the exposed contact region
to prevent diffusion of a material such as copper that will be used
to fill the opening. At 710, the opening is filled with the
conductive material or copper.
[0060] FIG. 8 illustrates an exemplary method 800 of forming a
first contact to a semiconductor device (e.g., during a FEOL
process). At 802, a substrate is provided. Isolation trench,
source/drain regions, gate stack and spacers are also formed in or
on the substrate. At 804, a silicide layer is formed over the
source/drain regions and optionally, the gate electrode layer of
the gate stack. At 806, a dielectric layer is formed immediately
above the top surface of the semiconductor device. Openings (having
a trench like configuration or a rectangular configuration) are
formed into the dielectric layer to expose the source/drain regions
and optionally, the gate electrode region. The openings can extend
the entire length of the device, for example, the openings exposing
the source/drain regions extend the entire length of the
source/drain regions. Alternatively, the opening only extends down
part of the device. In either the case of a full extension or a
partial extension, the opening may extend beyond the device over
the adjacent field. At 808, the opening is lined with a barrier
layer such that the barrier liner covers the exposed contact region
to prevent diffusion of a material such as copper that will be used
to fill the opening. At 810, a seed layer is optionally formed on
top of the barrier layer to initiate nucleation for the formation
of the copper in the openings. At 812, the openings are filled with
the conductive material or copper using electroplating or
electroless plating.
[0061] FIG. 9 illustrates an exemplary method 900 of forming a
first contact to a semiconductor device (e.g., during a FEOL
process). At 902, a substrate is provided. Isolation trench,
source/drain regions, gate stack and spacers are also formed in or
on the substrate. At 904, a dielectric layer is formed immediately
above the top surface of the semiconductor device. Openings (having
a trench like configuration or a rectangular configuration) are
formed into the dielectric layer to expose the source/drain regions
and optionally, the gate electrode region. The openings can extend
the entire length of the device, for example, the openings exposing
the source/drain regions extend the entire length of the
source/drain regions. Alternatively, the opening only extends down
part of the device. In either the case of a full extension or a
partial extension, the opening may extend beyond the device over
the adjacent field. At 906, a metal is added to permit formation of
a silicide on the exposed silicon region. Using processing known in
the art, the metal is annealed and a silicide layer is formed over
the source/drain regions and optionally, the gate electrode layer
of the gate stack. The opening is optionally lined with a barrier
layer such that the barrier liner covers the exposed contact region
to prevent diffusion of a material such as copper that will be used
to fill the opening. At 910, a seed layer is optionally formed on
top of the copper silicide layer to initiate nucleation for the
formation of the copper in the openings. At 912, the openings are
filled with the conductive material or copper using electroplating
or electroless plating.
[0062] Embodiments of the present invention permit more flexibility
in the placement of via connector and/or metalizations to a device
while providing superior performance over conventional
configuration of interconnection to a device. For instance, in one
embodiment, (as the state of the art or conventional devices with
round contacts does not even permit this configuration) a via
connector such as the via connector 222 is located adjacent to the
device on the adjacent field and connects to the device through the
extension of a first contact such as the contact 220 onto the
field. In this configuration the high conductivity of the trench
contact style for the first contact provides significant
performance improvement. Experimental results from devices
fabricated with copper-contacts in this exemplary configuration
show for NMOS up to 35% Idsat and 50% IDlin improvement, and for
PMOS up to 30% Idsat and 50% IDlin improvement; when compared to
conventional W processing in the same geometry. If the W processing
is enhanced to the limit of the state of the art (i.e.
configurations unrealistic for mass production), improvements are
still seen for NMOS up to 15% Idsat and 25% IDlin improvement, and
for PMOS up to 10% Idsat and 20% IDlin improvement; when compared
to conventional W processing in the same geometry.
[0063] Although embodiments above focus mainly on FEOL processing,
the same can be applied to BEOL processing without exceeding the
scope of the embodiments of the present invention.
[0064] Having thus described in detail embodiments of the present
invention, it is understood that the invention defined by the
appended claims is not to be limited by particular details set
forth in the above description, as many apparent variations thereof
are possible without departing from the spirit or scope
thereof.
* * * * *