U.S. patent application number 14/621660 was filed with the patent office on 2016-08-18 for method of fabricating semiconductor device.
The applicant listed for this patent is Taiwan Semiconductor Manufacturing Company, Ltd.. Invention is credited to Chun-Kuang Chen, Kuei-Shun Chen, Tsai-Sheng Gau, Chung-Ju Lee, Ru-Gun Liu, Shau-Lin Shue, Chia-Tien Wu, Yung-Hsu Wu, Yung-Sung Yen, Ta-Ching Yu.
Application Number | 20160240430 14/621660 |
Document ID | / |
Family ID | 56556003 |
Filed Date | 2016-08-18 |
United States Patent
Application |
20160240430 |
Kind Code |
A1 |
Yen; Yung-Sung ; et
al. |
August 18, 2016 |
METHOD OF FABRICATING SEMICONDUCTOR DEVICE
Abstract
A method for fabricating a semiconductor device includes forming
a hard mask (HM) layer over a material layer, forming a first
trench in the HM layer, which extends along a first direction. The
method also includes forming a first patterned resist layer over
the HM layer. The first patterned resist layer has a first opening
and a second opening a second direction. The first opening overlaps
with the first trench in a middle portion of the first trench and
the second opening overlaps with the first trench at an end portion
of the first trench. The method also includes etching the HM layer
through the first patterned resist layer to form a second trench
and a third trench in the HM layer and forming a first feature to
fill in a section of the first trench between the second trench and
the third trench.
Inventors: |
Yen; Yung-Sung; (New Taipei
City, TW) ; Lee; Chung-Ju; (Hsinchu City, TW)
; Chen; Chun-Kuang; (Hsinchu County, TW) ; Wu;
Chia-Tien; (Taichung City, TW) ; Yu; Ta-Ching;
(Hsinchu County, TW) ; Chen; Kuei-Shun; (Hsinchu
City, TW) ; Liu; Ru-Gun; (Hsinchu County, TW)
; Shue; Shau-Lin; (Hsinchu, TW) ; Gau;
Tsai-Sheng; (HsinChu City, TW) ; Wu; Yung-Hsu;
(Taipei City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Taiwan Semiconductor Manufacturing Company, Ltd. |
Hsin-Chu |
|
TW |
|
|
Family ID: |
56556003 |
Appl. No.: |
14/621660 |
Filed: |
February 13, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 21/76802 20130101;
H01L 21/76816 20130101; H01L 21/76811 20130101; H01L 21/32139
20130101; H01L 21/31144 20130101; H01L 21/3088 20130101; H01L
21/0274 20130101 |
International
Class: |
H01L 21/768 20060101
H01L021/768; H01L 23/538 20060101 H01L023/538; H01L 21/033 20060101
H01L021/033; H01L 21/311 20060101 H01L021/311 |
Claims
1. A method comprising: forming a hard mask (HM) layer over a
material layer; forming a first trench in the HM layer, wherein the
first trench extends along a first direction; forming a first
patterned resist layer over the HM layer, wherein the first
patterned resist layer has a first opening and a second opening
such that: the first opening extends along a second direction that
is perpendicular to the first direction, the first opening overlaps
with the first trench in a middle portion of the first trench; the
second opening is parallel to the first opening and overlaps with
the first trench at an end portion of the first trench; etching the
HM layer through the first patterned resist layer to form a second
trench and a third trench in the HM layer; and forming a first
feature to fill in a section of the first trench between the second
trench and the third trench.
2. The method of claim 1, further comprising: after forming the
first feature, etching the material layer, by using the HM layer as
an etch mask, to transfer the first trench, the second trench and
third trench to the material layer.
3. The method of claim 1, wherein the first trench connects to the
second trench with an angle of about 90 degree.
4. The method of claim 1, further comprising: during forming the
first trench in the HM layer, forming a fourth trench in the HM
layer, wherein the fourth trench is parallel to the first
trench.
5. The method of claim 4, wherein the first opening overlaps with
the first trench at one end and with the fourth trench at another
end.
6. The method of claim 5, wherein the second trench overlaps with
the first trench at one end and with the fourth trench at another
end.
7. The method of claim 6, further comprising forming a second
feature to fill in a second of the second trench along a side of
the fourth trench facing to the first trench.
8. The method of claim 7, further comprising: after forming the
second feature, etching the material layer, by using the HM layer
as an etch mask, to transfer the fourth trench to the material
layer.
9. The method of claim 8, wherein the fourth trench in the material
layer is separated to the second trench in the material layer.
10. The method of claim 1, wherein forming the first feature to
fill in the section of the first trench between the second trench
and the third trench includes: depositing a sacrificial layer over
the HM layer, including filling in the first trench; forming a
second pattern resist layer to cover a portion of the sacrificial
layer; and etching the sacrificial layer through the second
patterned resist layer, wherein the sacrificial layer covered by
the second patterned resist layer remains.
11. The method of claim 1, further comprising extending the first
opening in the first patterned resist layer to outside the first
trench.
12. A method comprising: forming a hard mask (HM) layer over a
material layer; forming a first trench and a second trench in the
HM layer, wherein the first trench the first trench is along a
first direction, wherein the second trench is parallel to the first
trench; forming a first patterned resist layer having a first
opening and a second opening over the HM layer such that: the first
opening is along a second direction, which is perpendicular to the
first direction, wherein it overlaps with the first trench in a
middle of the first trench and overlaps with the second trench; the
second opening is parallel to the first opening and overlaps with
the first trench at an end of the first trench; etching the HM
layer through the first patterned resist layer to form a third
trench and a fourth trench respectively in the HM layer; and
forming a first feature to fill in a section of the first trench
between the third trench and the fourth trench and a second feature
to fill in a section of the third trench along a side of the second
trench facing towards to the first trench.
13. The method of claim 12, further comprising: after forming the
first feature and the second feature, etching the material layer,
by using the HM layer as an etch mask, to transfer the first
trench, the second trench, the third trench and fourth trench to
the material layer.
14. The method of claim 12, wherein the first trench connects to
the third trench with an angle of about 90 degree.
15. The method of claim 13, wherein the second trench in the
material layer is separated to the third trench in the material
layer.
16. The method of claim 12, wherein forming the first feature to
fill in the section of the first trench between the third trench
and the fourth trench and the second feature to fill in the section
of the third trench along the side of the second trench facing
towards to the first trench includes: depositing a sacrificial
layer over the HM layer, including filling in the first trench and
the third trench; forming a second pattern resist layer to cover
respective portions of the sacrificial layer; and etching the
sacrificial layer through the second patterned resist layer,
wherein the portions of the sacrificial layer covered by the second
patterned resist layer remain.
17. The method of claim 12, further comprising extending the first
opening to outside the first trench in the first patterned resist
layer.
18. The method of claim 12, further comprising transferring the
extended first opening to an extended third trench in the material
layer.
19-20. (canceled)
21. A method comprising: forming a hard mask (HM) layer over a
material layer; forming a first trench in the HM layer, wherein the
first trench extends along a first direction; forming a first
patterned resist layer over the HM layer, wherein the first
patterned resist layer has a first opening and a second opening
such that: the first opening extends along a second direction that
is perpendicular to the first direction, the first opening overlaps
with the first trench in a first portion of the first trench; the
second opening is parallel to the first opening and overlaps with
the first trench at an second portion of the first trench; etching
the HM layer through the first patterned resist layer to form a
second trench and a third trench in the HM layer; and forming a
first feature to fill in a section of the first trench between the
second trench and the third trench.
22. The method of claim 1, further comprising: after forming the
first feature, etching the material layer, by using the HM layer as
an etch mask, to transfer the first trench, the second trench and
third trench to the material layer.
Description
BACKGROUND
[0001] The semiconductor integrated circuit (IC) industry has
experienced rapid growth. Technological advances in IC design and
material have produced generations of ICs where each generation has
smaller and more complex circuits than previous generations. In the
course of IC evolution, functional density (i.e., the number of
interconnected devices per chip area) has generally increased while
geometry size (i.e., the smallest component (or line) that can be
created using a fabrication process has decreased. When a
semiconductor device such as a metal-oxide-semiconductor
field-effect transistor (MOSFET) is scaled down through various
technology nodes, challenges rise to reduce
irregularities/distortions in features/patterns formed over a
wafer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Aspects of the present disclosure are best understood from
the following detailed description when read in association with
the accompanying figures. It is noted that, in accordance with the
standard practice in the industry, various features in drawings are
not drawn to scale. In fact, the dimensions of illustrated features
may be arbitrarily increased or decreased for clarity of
discussion.
[0003] FIG. 1 is a flowchart of an example method for fabricating a
semiconductor device constructed in accordance with some
embodiments.
[0004] FIG. 2 is a cross section view of an example of a workpiece
of a semiconductor device in accordance with some embodiments.
[0005] FIGS. 3A and 3B are schematic views of patterns formed over
a resist layer by a lithography process.
[0006] FIG. 4A is a top view of an example of a semiconductor
device in accordance with some embodiments.
[0007] FIG. 4B is a cross-sectional view of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIG. 4A.
[0008] FIG. 5A is a top view of an example of a semiconductor
device in accordance with some embodiments.
[0009] FIG. 5B is a cross-sectional view of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIG. 5A.
[0010] FIGS. 6A and 6C are top views of an example of a
semiconductor device in accordance with some embodiments.
[0011] FIGS. 6B and 6D are cross-sectional views of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIGS. 6A and 6C, respectively.
[0012] FIGS. 7A and 7C are top views of an example of a
semiconductor device in accordance with some embodiments.
[0013] FIGS. 7B and 7D are cross-sectional views of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIGS. 7A and 7C, respectively.
[0014] FIGS. 8A and 8C are top views of an example of a
semiconductor device in accordance with some embodiments.
[0015] FIGS. 8B and 8D are cross-sectional views of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIGS. 8A and 8C, respectively.
[0016] FIGS. 9A and 9C are top views of an example of a
semiconductor device in accordance with some embodiments.
[0017] FIGS. 9B and 9D are cross-sectional views of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIGS. 9A and 9C, respectively.
[0018] FIGS. 10A and 10C are top views of an example of a
semiconductor device in accordance with some embodiments.
[0019] FIGS. 10B and 10D are cross-sectional views of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIGS. 10A and 10C, respectively.
[0020] FIGS. 11A and 11C are top views of an example of a
semiconductor device in accordance with some embodiments.
[0021] FIGS. 11B and 11D are cross-sectional views of an example
semiconductor device in accordance with some embodiments, along the
line A-A in FIGS. 11A and 11C, respectively.
DETAILED DESCRIPTION
[0022] The following disclosure provides many different
embodiments, or examples, for implementing different features of
the invention. Specific examples of components and arrangements are
described below to simplify the present disclosure. These are, of
course, merely examples and are not intended to be limiting. For
example, the formation of a first feature over or on a second
feature in the description that follows may include embodiments in
which the first and second features are formed in direct contact,
and may also include embodiments in which additional features may
be formed between the first and second features, such that the
first and second features may not be in direct contact. In
addition, the present disclosure may repeat reference numerals
and/or letters in various examples. This repetition is for the
purpose of simplicity and clarity and does not in itself dictate a
relationship between the various embodiments and/or configurations
discussed.
[0023] Further, spatially relative terms, such as "beneath,"
"below," "lower," "above," "upper" and the like, may be used herein
for ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as illustrated in
the figures. The spatially relative terms are intended to encompass
different orientations of the device in use or operation in
addition to the orientation depicted in the figures. The apparatus
may be otherwise oriented (rotated 90 degrees or at other
orientations) and the spatially relative descriptors used herein
may likewise be interpreted accordingly.
[0024] FIG. 1 is a flowchart of a method 100 of fabricating one or
more semiconductor devices in accordance with some embodiments. The
method 100 is discussed in detail below, with reference to a
workpiece 205 of a semiconductor device 200 shown in FIG. 2 and the
semiconductor device 200, shown in FIGS. 4A to 11D.
[0025] Referring to FIGS. 1 and 2, the method 100 starts at step
102 by receiving a workpiece 205 of the semiconductor device 200.
The workpiece 205 includes a substrate 210. The substrate 210 may
be a bulk silicon substrate. Alternatively, the substrate 210 may
comprise an elementary semiconductor, such as silicon (Si) or
germanium (Ge) in a crystalline structure; a compound
semiconductor, such as silicon germanium (SiGe), silicon carbide
(SiC), gallium arsenic (GaAs), gallium phosphide (GaP), indium
phosphide (InP), indium arsenide (InAs), and/or indium antimonide
(InSb); or combinations thereof. Possible substrates 210 also
include a silicon-on-insulator (SOI) substrate. SOI substrates are
fabricated using separation by implantation of oxygen (SIMOX),
wafer bonding, and/or other suitable methods.
[0026] Some exemplary substrates 210 also include an insulator
layer. The insulator layer comprises any suitable material,
including silicon oxide, sapphire, and/or combinations thereof. An
exemplary insulator layer may be a buried oxide layer (BOX). The
insulator is formed by any suitable process, such as implantation
(e.g., SIMOX), oxidation, deposition, and/or other suitable
process. In some exemplary semiconductor device 200, the insulator
layer is a component (e.g., layer) of a silicon-on-insulator
substrate.
[0027] The substrate 210 may also include various p-type doped
regions and/or n-type doped regions, implemented by a process such
as ion implantation and/or diffusion. Those doped regions include
n-well, p-well, light doped region (LDD), doped source and drain
(S/D), and various channel doping profiles configured to form
various integrated circuit (IC) devices, such as a complimentary
metal-oxide-semiconductor field-effect transistor (CMOSFET),
imaging sensor, and/or light emitting diode (LED). The substrate
210 may further include other functional features such as a
resistor or a capacitor formed in and on the substrate.
[0028] The substrate 210 may also include various isolation
features. The isolation features separate various device regions in
the substrate 210. The isolation features include different
structures formed by using different processing technologies. For
example, the isolation features may include shallow trench
isolation (STI) features. The formation of a STI may include
etching a trench in the substrate 210 and filling in the trench
with insulator materials such as silicon oxide, silicon nitride, or
silicon oxynitride. The filled trench may have a multi-layer
structure such as a thermal oxide liner layer with silicon nitride
filling the trench. A chemical mechanical polishing (CMP) may be
performed to polish back excessive insulator materials and
planarize the top surface of the isolation features.
[0029] The substrate 210 may also include gate stacks formed by
dielectric layers and electrode layers. The dielectric layers may
include an interfacial layer (IL) and a high-k (HK) dielectric
layer deposited by suitable techniques, such as chemical vapor
deposition (CVD), atomic layer deposition (ALD), physical vapor
deposition (PVD), thermal oxidation, combinations thereof, or other
suitable techniques. The electrode layers may include a single
layer or multi layers, such as metal layer, liner layer, wetting
layer, and adhesion layer, formed by ALD, PVD, CVD, or other
suitable process.
[0030] The substrate 210 may also include a plurality of
inter-level dielectric (ILD) layers and conductive features
integrated to form an interconnect structure configured to couple
the various p-type and n-type doped regions and the other
functional features (such as gate electrodes), resulting a
functional integrated circuit.
[0031] In the present embodiment, the workpiece 205 includes a
material layer 220 over the substrate 210 and a hard mask (HM) 310
deposited over the material layer 220. The material layer 220 may
include a dielectric layer, such as silicon oxide, silicon nitride,
or silicon oxynitride, low-k dielectric material, or other suitable
materials. The material layer 220 may also include a conductive
layer such as a polysilicon, a metal layer, or/and other suitable
material. The HM 310 may include silicon oxide, silicon nitride,
oxynitride, silicon carbide, titanium oxide, titanium nitride,
tantalum oxide, tantalum nitride, and/or any suitable materials. In
the present embodiment, the HM 310 may include a material which is
different from the material layer 220 to achieve etching
selectivity during subsequent etch processes. The material layer
220 and the HM 310 may be deposited over the substrate 210 by
suitable techniques, such as chemical vapor deposition (CVD),
atomic layer deposition (ALD), physical vapor deposition (PVD),
thermal oxidation, combinations thereof, or other suitable
techniques.
[0032] In the present embodiment, a plurality of features (e.g.
trenches) is to be formed in the material layer 220. In order to
form trenches in the material layer 220, it is usually to form a
patterned resist layer with openings over the HM 310 first, then
etching the HM 310 through openings to pattern the HM 310, and then
etching the material layer 220 through the patterned HM 310 to form
trenches. The patterned resist layer may be formed by a lithography
process equipped with an optical imaging tool.
[0033] FIG. 3A shows an ideal patterned resist layer 330 which
includes a first opening 340 having a L-shape, that has a first
portion 340A extending along a first direction (Y direction) and a
second portion 340B extending along a second direction (X
direction), which is perpendicular to the first direction. The
first portion 340A connects to the second portion 340B at a
location A. It is desired that the first portion 340A connects to
the second portion 340B with a right angle (90 degree) at the
location A. The patterned resist layer 330 also includes a second
opening 350 and a third opening 360. For example, the second
opening 350 is located close to an end of the second portion 340B
of the first opening 340 at a location B. The third opening 360 is
located close to the second portion 340B of the first opening 340
at a location C. It desired that each of opening, 340, 350 and 360,
remain regular contour (such as a rectangular contour) at each end
of the openings.
[0034] However, due to diffraction, resolution and other process
effect of the optical imaging tool in a lithography process,
irregularities/distortions in resist patterns (openings) may
happen. FIG. 3B shows such problems that can occur to patterned
resist layer 330. For example, when the first portion 340A and the
second portion 340B of the first opening 340 are formed over a
resist layer, a rounded corner distortion may be formed and the
first portion 340A connects to the second portion 340B with a
rounded angle at the location A. Furthermore, when the first,
second and third openings, 340, 350 and 360 locate closely to each
other such that a distance between them is smaller than a threshold
distance d.sub.th of a lithography exposure process, they may have
line end shortening distortions at locations, such as the location
B and the location C. If these irregularities/distortions are
transferred to form features (such as trenches) over a layer (such
as the material layer 220) the substrate 210, it may significantly
alter the electrical properties of the semiconductor device 200.
The present discourse provides methods to reduce
irregularities/distortions in forming trenches in the material
layer 220.
[0035] Referring to FIGS. 1 and 4A-4B, once the workpiece 205 is
received, method 100 proceeds to step 104 by performing a first
lithography process to form a first patterned resist layer 410 over
the HM 310. The first patterned resist layer 410 has a first
opening 415 and a second opening 416. Respective portions of the HM
310 are exposed in the first and second openings, 415 and 416. In
the present embodiment, both of the first and second openings, 415
and 416, have rectangular shapes and extends along the Y-direction.
An exemplary lithography process may include forming a resist
layer, exposing the resist layer by a lithography exposure process,
performing a post-exposure bake process, and developing the resist
layer to form the patterned resist layer. In some embodiments, a
first distance d.sub.1 between the first opening 415 and the second
opening 416 is chosen to be greater than a threshold distance
d.sub.th of the lithography exposing process. Thus, the first and
second openings, 415 and 416, are formed with regular contours
(such as rectangular contours) at their opening ends: a first
opening end I, a second opening end J, the third opening end K and
a fourth opening end L, respectively.
[0036] Referring to FIGS. 1 and 5A-5B, method 100 proceeds to step
106 by etching the HM 310 through the first patterned resist 410 to
transfer the first and second openings, 415 and 416, to a first and
second trenches, 425 and 426, in the HM 310, respectively. In some
embodiments, the etch process includes an anisotropic dry etch. For
example, the etch process is a plasma anisotropic etch. Therefore,
regular contours of the first, second, third and fourth opening
ends, I, J, K and L are transferred to a first, second, third and
fourth trench ends, I', J', K' and L', respectively. In some
embodiments, the etch process is properly chosen to selectively
remove the HM 310 but does not substantially etch the material
layer 220. As has been mentioned previously, with an adequate etch
selectivity, the material layer 220 serves as an etch stop layer,
which improves etch process window and profile control. A resist
strip process is then applied to remove any remaining first
patterned resist layers 410.
[0037] Referring to FIGS. 1 and 6A-6B, the method 100 proceeds to
step 108 by performing a second lithography process to form a
second patterned resist layer 510 over the HM 310. The second
patterned resist layer 510 has a third opening 515 and a fourth
opening 516. In the present embodiment, both of the third and
fourth openings, 515 and 516, extends along the X direction. The
third opening 515 overlaps and extends perpendicularly with respect
to the first trench 425 at a first location M. A portion of the
first trench 425 is exposed within the third opening 515. The third
opening 515 also overlaps and extends perpendicularly with respect
to the second trench 426 at the third trench end K'. A respective
portion of the second trench 426 is exposed within the third
opening 515. The fourth opening 516 overlaps and extends
perpendicularly with respect to the first trench 425 at the second
trench end F. A respective portion of the first trench 425 is
exposed within the fourth opening 516. The second patterned resist
layer 510 is formed similarly in many respects to the first
patterned resist layer 410 discussed above association with FIGS.
4A-4B.
[0038] In some embodiments, at some locations, a second distance
d.sub.2 between the third opening 515 and adjacent the fourth
opening 516 is smaller than the threshold distance d.sub.th and
irregularities/distortions (e.g. line end shortening) may happen
for the third and fourth openings, 515 and 516, respectively. For
example, the fourth opening 516 may have a line end shortening at
its opening end at the first location M and a second location N.
But these line end shortenings may not be transferred to trenches
to be formed in the HM 310 at the first and second locations, M and
N, which will be described in more detail below.
[0039] Referring to FIGS. 6C and 6D, in some embodiments, the third
opening 515 and the fourth opening 516 extend to outside of the
first trench 425 at the first and second location, M and N,
respectively. They may provide insurance-like portions for line end
distortion at respective opening ends of third and fourth openings,
515 and516, with the first trench 425 at the first and second
location, M and N, respectively. The extending portions of the
third and fourth openings, 515 and 516, are referred to as the
extending openings, 515A and 516A, respectively. As an example, the
extending openings, 515A and 516A have a third distance d.sub.3. In
some other embodiments, the third opening 515 and the fourth
opening 516 may have extending openings at the third trench end K'
as well.
[0040] Referring to FIGS. 1 and 7A-7B, method 100 proceeds to step
110 by etching the HM 310 through the second patterned resist 510
to transfer the third and fourth openings, 515 and 516, to a third
and a fourth trenches, 525 and 526 in the HM 310, respectively. The
HM 310 is etched similarly in many respects to the etching process
first patterned discussed above association with FIGS. 5A-5B. The
etch process is properly chosen to selectively remove the HM 310
but does not substantially etch the material layer 220. A resist
strip process is then applied to remove any remaining second
patterned resist layers 510.
[0041] In the present embodiment, at the first location M, the
third trench 525 overlaps perpendicularly with the first trench 425
with an angle .theta. to form a L-shape trench. Since the first
trench 425 is formed by the first etch process through the first
patterned resist layer 410 and the second trench 525 is formed by
the second etch process through the second patterned resist layer
510, irregularities/distortions (e.g. rounded corner) at the first
location M caused by each of lithography processes are greatly
reduced and the angle .theta. is about 90 degree. At the second
location N, as has been mentioned previously, a final trench end
contour may be defined by the first trench 425. Thus, a line end
shortening in the fourth opening 516 may not affect trench end
contour of the first trench 425 at the second location N.
[0042] Referring to FIGS. 7C-7D, in some embodiments, the extending
openings 515A and 516A are transferred to extending trenches 525A
and 526A respectively as well.
[0043] Referring to FIGS. 1 and 8A -8B, method 100 proceeds to step
112 by depositing a sacrificial layer 610 to fill in the first,
second, third and fourth trenches, 425, 426, 525 and 526. The
sacrificial layer 610 may include spin-on glass, silicon oxide,
silicon nitride, oxynitride, silicon carbide, and/or other suitable
materials. In one embodiment, the sacrificial layer 610 includes a
material which is different from the material layer 220 and the HM
310 to achieve etching selectivity subsequent etches. The
sacrificial layer 610 may be deposited by CVD, PVD, ALD, spin-on
coating, or other suitable techniques. In the one embodiment, the
sacrificial layer 610 is then etched back to planarize with
surfaces of the HM 310.
[0044] Referring to FIGS. 8C-8D, in some embodiments, the
sacrificial layer 610 fills in the extending trenches 525A and 526A
respectively as well.
[0045] Referring to FIGS. 1 and 9A -9B, method 100 proceeds to step
114 by forming a first and second resist blocks, 715 and 716, over
the sacrificial layer 610. The first resist block 715 is aligned to
the first trench 425 such that it covers a respective portion of
the first trench 425 between the third trench 525 and the fourth
trench 526 (between the first location M and the second location
N). The second resist block 716 is aligned to the third trench 525
such that it is along a side of the second trench 426. In some
embodiment, a distance between the first resist block 715 and the
second resist block 716 is chosen to be greater than a threshold
distance d.sub.th of the lithography exposing process. Thus, the
first and second resist block, 715 and 716, are formed with regular
contours (such as a rectangular contour). The first and second
resist blocks, 715 and 716, may be formed by performing a third
lithography process, which is similarly in many respects to forming
the first patterned resist layer 410 discussed above association
with FIGS. 4A-4B.
[0046] FIGS. 9C-9D show that, in some embodiments, the first resist
block 715 is aligned to the first trench 425 and covers the
respective portion of the first trench 425 between the third trench
525 and the fourth trench 526, which has the extending trench 526A.
And the second resist block 716 is aligned to the third trench 525
having the extending trench 525A, such that it is along a side of
the second trench 426.
[0047] Referring to FIGS. 1 and 10A -10B, method 100 proceeds to
step 116 by etching the sacrifice layer 610 to transfer the first
and second resist blocks, 715 and 725, to a first and second
trench-filler-feature (TFF), 725 and 726, respectively. The first
TFF 725 separates the first trench 425 from the fourth trench 526.
That is, the first TFF 725 serves as a sidewall of the third trench
525 at the first location M and a sidewall of the fourth trench 526
at the second location N. And the second TFF 726 separates the
second trench 426 from the third trench 525. That is, the second
TFF 726 serves as a sidewall of the second trench 426 at a third
location P and as a sidewall of the third trench 525 at the third
location P. The etch process is properly chosen to selectively
remove the sacrificial layer 610 but does not substantially etch
the HM 310 and the material layer 220. The first and second resist
blocks, 715 and 716, are removed by another etch process.
[0048] FIGS. 10C-10D show that, in some embodiments, the first TFF
725 separates the first trench 425 from the fourth trench 526
having the extending trench 526A and the second TFF 726 separates
the second trench 426 from the third trench 525 having the
extending trench 525A.
[0049] Referring to FIGS. 1 and 11A-11B, method 100 proceeds to
step 118 by etching the material layer 220 by using the HM 310 as
an etch mask to transfer the first, second, third and fourth
trenches, 425, 426, 525 and 526, to a fifth, sixth, seventh and
eighth trenches, 810, 820, 830 and 840, respectively, in the
material layer 220. In some embodiment, respective portions of the
substrate 210 are exposed in the fifth, sixth, seventh and eighth
trenches, 810, 820, 830 and 840. In present embodiment, the etch
process includes an anisotropic dry etch. For example, the etch
process is a plasma anisotropic etch. The HM 310 is then removed by
a proper etch process.
[0050] Referring again to FIG. 11B, thus the material layer 220 has
the fifth, sixth, seventh and eighth trenches, 810, 820, 830 and
840, such that the fifth trench 810 connects to the seventh trench
830 with the 90-degree connecting angle .theta. to form a L-shape
trench; the sixth trench 820 is parallel to the fifth trench 810
and has a trench end V adjacent to a trench end X of the seventh
trench 830; the eighth trench 840 is parallel to the seventh trench
830 and has a trench end Y adjacent to the fifth trench 810. All of
trench ends, V, X and Y are formed with regular contours (such as a
rectangular contour).
[0051] FIGS. 11C-11D show that, in some embodiments, the seventh
trench 830 has the trench end V extending outside the fifth trench
810 by the third distance d.sub.3. In other words, the seventh
trench 830 has a short portion 830A extending outside of one side
of the fifth trench 810 and a long portion 830B extending outside
of another side of the fifth trench 810.
[0052] Additional steps can be provided before, during, and after
the method 100, and some of the steps described can be replaced,
eliminated, or moved around for additional embodiments of the
method 100. Other alternatives or embodiments may present without
departure from the spirit and scope of the present disclosure.
[0053] The semiconductor device 200 may undergo further CMOS or MOS
technology processing to form various features and regions known in
the art. For example, subsequent processing may form metal lines in
the fifth, sixth, seventh and eighth trenches, 810, 820, 830 and
840. For another example, various contacts/vias and multilayers
interconnect features (e.g., interlayer dielectrics) over the
substrate 210, configured to connect the various features or
structures of the semiconductor device 200.
[0054] Based on the above, it can be seen that the present
disclosure provides methods of forming L-shape trenches and
trenches which have small space between each other. The method uses
multiple lithography/etch cycles to forming trenches such that in
each lithography/etch cycle trenches are formed along a same
direction. The method also employs forming trench-filling-feature
to define respective trench ends. The method demonstrates reducing
rounded corner distortion in forming the L-shape trench and
reducing line end shortening distortion in forming trenches having
small spacing between each other.
[0055] The present disclosure provides many different embodiments
of fabricating a semiconductor device that provide one or more
improvements over existing approaches. In one embodiment, a method
for fabricating a semiconductor device includes forming a hard mask
(HM) layer over a material layer, forming a first trench in the HM
layer, which extends along a first direction. The method also
includes forming a first patterned resist layer over the HM layer.
The first patterned resist layer has a first opening and a second
opening such that the first opening extends along a second
direction that is perpendicular to the first direction and overlaps
with the first trench in a middle portion of the first trench; the
second opening is parallel to the first opening and overlaps with
the first trench at an end portion of the first trench. The method
also includes etching the HM layer through the first patterned
resist layer to form a second trench and a third trench in the HM
layer and forming a first feature to fill in a section of the first
trench between the second trench and the third trench.
[0056] In another embodiment, a method includes forming a hard mask
(HM) layer over a material layer, forming a first trench and a
second trench in the HM layer. The first trench extends along a
first direction and the second trench is parallel to the first
trench. The method also includes forming a first patterned resist
layer having a first opening and a second opening over the HM layer
such that the first opening extends along a second direction, which
is perpendicular to the first direction. The first opening overlaps
with the first trench in a middle of the first trench and overlaps
with the second trench in an end of the second trench; the second
opening is parallel to the first opening and overlaps with the
first trench at an end of the first trench. The method also
includes etching the HM layer through the first patterned resist
layer to form a third trench and a fourth trench respectively in
the HM layer and forming a first feature to fill in a section of
the first trench between the third trench and the fourth trench and
a second feature to fill in a section of the third trench along a
side of the second trench facing towards to the first trench.
[0057] In yet another embodiment, a device includes a first trench
extends along a first direction in a material layer and a second
trench extends along a second direction in the material layer,
which is perpendicular to the first direction. The second trench
connects to the first trench such that a short portion of the first
trench extends outside of one side of the first trench and a long
portion of the first trench extends outside of another side of the
first trench.
[0058] The foregoing outlines features of several embodiments so
that those skilled in the art may better understand the aspects of
the present disclosure. Those skilled in the art should appreciate
that they may readily use the present disclosure as a basis for
designing or modifying other processes and structures for carrying
out the same purposes and/or achieving the same advantages of the
embodiments introduced herein. Those skilled in the art should also
realize that such equivalent constructions do not depart from the
spirit and scope of the present disclosure, and that they may make
various changes, substitutions, and alterations herein without
departing from the spirit and scope of the present disclosure.
* * * * *