U.S. patent application number 15/652508 was filed with the patent office on 2019-01-24 for patterning for substrate fabrication.
The applicant listed for this patent is Taiwan Semiconductor Manufacturing Co., Ltd.. Invention is credited to Chun-Wei Chang, Wei-Chao Chiu, Ching-Sen Kuo, Feng-Jia Shiu, Kai Tzeng, Chih-Chien Wang, Cheng-Ta Wu.
Application Number | 20190027519 15/652508 |
Document ID | / |
Family ID | 65011543 |
Filed Date | 2019-01-24 |
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United States Patent
Application |
20190027519 |
Kind Code |
A1 |
Chiu; Wei-Chao ; et
al. |
January 24, 2019 |
Patterning for Substrate Fabrication
Abstract
Various examples of a technique for forming a pattern for
substrate fabrication are disclosed herein. In an example, a method
includes receiving a substrate. A patterned resist is formed on the
substrate and has a trench defined therein. A dielectric is
deposited on the patterned resist and within the trench such that
the dielectric narrows a width of the trench to further define the
trench. A fabrication process is performed on a region of the
substrate underlying the trench defined by the dielectric.
Inventors: |
Chiu; Wei-Chao; (Hsinchu,
TW) ; Tzeng; Kai; (Pingtung County, TW) ;
Wang; Chih-Chien; (Changhua County, TW) ; Chang;
Chun-Wei; (Tainan City, TW) ; Kuo; Ching-Sen;
(Taipei City, TW) ; Shiu; Feng-Jia; (Hsinchu
County, TW) ; Wu; Cheng-Ta; (Chiayi County,
TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Taiwan Semiconductor Manufacturing Co., Ltd. |
Hsinchu |
|
TW |
|
|
Family ID: |
65011543 |
Appl. No.: |
15/652508 |
Filed: |
July 18, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 21/0274 20130101;
H01L 27/14683 20130101; H01L 27/1463 20130101; G03F 7/168 20130101;
G03F 7/2004 20130101; G03F 7/32 20130101; G03F 7/095 20130101; G03F
7/094 20130101; G03F 7/11 20130101; H01L 21/761 20130101; G03F 7/40
20130101; G03F 7/38 20130101; G03F 7/162 20130101; H01L 21/3086
20130101; H01L 21/26513 20130101 |
International
Class: |
H01L 27/146 20060101
H01L027/146; H01L 21/761 20060101 H01L021/761; H01L 21/027 20060101
H01L021/027; H01L 21/265 20060101 H01L021/265; G03F 7/09 20060101
G03F007/09; G03F 7/095 20060101 G03F007/095; G03F 7/11 20060101
G03F007/11 |
Claims
1. A method comprising: receiving a substrate; forming a patterned
resist on the substrate, wherein the patterned resist has a trench
defined therein; depositing a dielectric on the patterned resist
and within the trench such that the dielectric narrows a width of
the trench to further define the trench, wherein the depositing of
the dielectric is performed at a temperature between about
20.degree. C. and about 100.degree. C.; and performing a
fabrication process on a region of the substrate underlying the
trench defined by the dielectric.
2. The method of claim 1, wherein: the fabrication process includes
an ion-implantation process; and a thickness of the dielectric at a
bottom of the trench permits the ion-implantation process to
implant the region of the substrate through the dielectric.
3. The method of claim 2, wherein the ion-implantation process
forms a junction isolation region within the substrate.
4. The method of claim 3, wherein the junction isolation region
isolates a set of pixel regions of an image sensor.
5. (canceled)
6. The method of claim 1, wherein the depositing of the dielectric
includes a technique from a group consisting of catalyst enhanced
chemical vapor deposition and plasma enhanced chemical vapor
deposition.
7. The method of claim 1, wherein the depositing of the dielectric
is configured to deposit the dielectric substantially conformally
within the trench.
8. The method of claim 1, wherein the trench having the narrowed
width has a height-to-width ratio of greater than or equal to
13.
9. The method of claim 8, wherein the trench prior to the
depositing of the dielectric has a height-to-width ratio of less
than or equal to 10.
10. A method comprising: receiving a substrate; depositing a resist
material on the substrate; patterning the resist material to form a
first feature and a second feature with a trench disposed
therebetween; depositing a dielectric within the trench, wherein
the trench after the depositing of the dielectric has a
height-to-width ratio of greater than or equal to 13; and
performing a fabrication process on the substrate using the trench
having the dielectric deposited therein.
11. The method of claim 10, wherein: the fabrication process is
performed on a first region of the substrate; and the resist
material and a first portion of the dielectric on a sidewall of the
trench are configured to protect a second region of the substrate
from the fabrication process.
12. The method of claim 11, wherein: the fabrication process
includes an ion-implantation process; and a second portion of the
dielectric on a bottom of the trench above the first region of the
substrate is configured to implant the first region of the
substrate through the dielectric.
13. The method of claim 11, wherein: the fabrication process
includes an ion-implantation process; and the ion-implantation
process forms a junction isolation region within the substrate.
14. The method of claim 13, wherein the junction isolation region
isolates a set of pixel regions of an image sensor.
15. The method of claim 10, wherein the depositing of the
dielectric is performed at a temperature between about 20.degree.
C. and about 100.degree. C.
16. The method of claim 10, wherein the depositing of the
dielectric includes a technique from a group consisting of catalyst
enhanced chemical vapor deposition and plasma enhanced chemical
vapor deposition.
17. (canceled)
18. A method comprising: receiving a substrate; patterning a first
resist on the substrate to form a first feature; depositing a
dielectric on a side surface of the first feature; depositing a
second resist on the substrate to form a second feature separated
from the first feature by the dielectric; selectively removing the
dielectric to form a trench between the first feature and the
second feature; and selectively processing a portion of the
substrate exposed by the trench, wherein the selectively processing
includes: performing an ion-implantation process on the portion of
the substrate exposed by the trench to form a junction isolation
region the portion that isolates a set of pixel regions of an image
sensor.
19. The method of claim 18, wherein the dielectric is a first
dielectric, the trench is a first trench, and the first trench
extends in a first direction, the method further comprising:
patterning a third resist on the substrate to form a third feature;
depositing a second dielectric on a side surface of the third
feature; depositing a fourth resist on the substrate to form a
fourth feature separated from the third feature by the second
dielectric; selectively removing the second dielectric to form a
second trench between the third feature and the fourth feature,
wherein the second trench extends in a second direction
substantially perpendicular to the first direction; and selectively
processing the substrate exposed by the second trench.
20. (canceled)
21. The method of claim 1, wherein the patterned resist includes a
photoresist material and the dielectric physically contacts the
photoresist material.
22. The method of claim 21, wherein the depositing of the
dielectric is configured such that the deposited dielectric
physically contacts a top surface and opposing side surfaces of the
photoresist material.
23. The method of claim 22, wherein the depositing of the
dielectric is configured such that the deposited dielectric further
physically contacts the substrate, the method further comprising
removing a portion of the dielectric from the substrate prior to
the performing of the fabrication process.
Description
BACKGROUND
[0001] The semiconductor integrated circuit (IC) industry has
experienced rapid growth. 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. This scaling down process generally
provides benefits by increasing production efficiency and lowering
associated costs. However, such scaling down has also been
accompanied by increased complexity in design and manufacturing of
devices incorporating these ICs. Parallel advances in manufacturing
have allowed these increasingly complex designs to be fabricated
with precision and reliability.
[0002] As merely one example, advances in lithography have reduced
the sizes of circuit devices and enabled the formation of
increasingly complex structures. In general, lithography is the
formation of a pattern on a target. In one type of lithography,
referred to as photolithography, radiation such as ultraviolet
light passes through or reflects off a mask before striking a
photoresist coating on the target. The photoresist includes one or
more components that undergo a chemical transition when exposed to
radiation. A resultant change in property allows either the exposed
or the unexposed portions of the photoresist to be selectively
removed. In this way, photolithography transfers a pattern from the
mask onto the photoresist, which is then selectively removed to
reveal the pattern. The target then undergoes processing steps that
take advantage of the shape of the remaining photoresist to create
features on the target.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The present disclosure is best understood from the following
detailed description when read with the accompanying figures. It is
emphasized that, in accordance with the standard practice in the
industry, various features are not drawn to scale and are used for
illustration purposes only. In fact, the dimensions of the various
features may be arbitrarily increased or reduced for clarity of
discussion.
[0004] FIG. 1 is a flow diagram of a method of fabricating a
workpiece according to various aspects of the present
disclosure.
[0005] FIGS. 2A, 3A, 4A, 5A, 5C, and 6A are top-view diagrams of a
workpiece at various stages of a method of fabricating the
workpiece according to various aspects of the present
disclosure.
[0006] FIGS. 2B, 3B, 4B, 5B, 5D, and 6B are cross-sectional
diagrams of a workpiece at various stages of a method of
fabricating the workpiece according to various aspects of the
present disclosure.
[0007] FIGS. 7A and 7B are flow diagrams of a method of fabricating
a workpiece using orthogonal features according to various aspects
of the present disclosure.
[0008] FIGS. 8A, 9A, 10A, 11A, 12A, 13A, 14A, 15A, 16A, 17A, 18A,
19A, 20A, 21A, and 22A are top-view diagrams of a workpiece at
various stages of a method of fabricating the workpiece according
to various aspects of the present disclosure.
[0009] FIGS. 8B, 9B, 10B, 11B, 12B, 13B, 14B, 15B, 16B, 17B, 18B,
19B, 20B, 21B, and 22B are cross-sectional diagrams of a workpiece
at various stages of a method of fabricating the workpiece
according to various aspects of the present disclosure.
DETAILED DESCRIPTION
[0010] The following disclosure provides many different
embodiments, or examples, for implementing different features of
the disclosure. 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 the 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
beyond the extent noted.
[0011] Moreover, the formation of a feature on, connected to,
and/or coupled to another feature in the present disclosure that
follows may include embodiments in which the features are formed in
direct contact, and may also include embodiments in which
additional features may be formed interposing the features, such
that the features may not be in direct contact. In addition,
spatially relative terms, for example, "lower," "upper,"
"horizontal," "vertical," "above," "over," "below," "beneath,"
"up," "down," "top," "bottom," etc. as well as derivatives thereof
(e.g., "horizontally," "downwardly," "upwardly," etc.) are used for
ease of the present disclosure of one features relationship to
another feature. The spatially relative terms are intended to cover
different orientations of the device including the features.
[0012] As semiconductor fabrication technologies continue to
evolve, device sizes continue to shrink, thereby pushing the limits
of optics, chemistry, and physics. For example, device features may
be formed on a substrate by first applying a resist material and
lithographically exposing portions of the resist. A resultant
change in property allows either the exposed or the unexposed
portions of the resist to be selectively removed. A number of
factors determine the minimum feature size that may be formed
including capillary forces acting on the semisolid resist material.
Capillary forces may draw portions of a developed resist together
and cause the resist to collapse. This problem is exacerbated when
a resist pattern has a tall and narrow (i.e., high aspect ratio)
trench disposed in between resist features. Other properties of the
lithographic system, the resist, and the developing process may
also affect the quality of the resist at the trench boundaries. In
turn, the quality of the resist boundaries determines the precision
and uniformity of the features formed using the resist. In
contrast, collapsed resist may lead to narrowing, necking,
bridging, and other defects in the circuit. In this way and others,
resist performance directly affects the critical dimension (CD) of
integrated circuits and other aspects of circuit size and
quality.
[0013] As described below, the present disclosure provides a
technique to address these issues and to improve resist
performance. However, unless otherwise noted, no embodiment is
required to provide any particular advantage or to resolve any
particular aspect of resist collapse.
[0014] Some examples of the technique are described with reference
to FIGS. 1-6B. In that regard, FIG. 1 is a flow diagram of a method
100 of fabricating a workpiece according to various aspects of the
present disclosure. Additional steps can be provided before,
during, and after the method 100, and some of the steps described
can be replaced or eliminated for other embodiments of the method
100. FIGS. 2A, 3A, 4A, 5A, 5C, and 6A are top-view diagrams of the
workpiece 200 at various stages of the method 100 of fabricating
the workpiece 200 according to various aspects of the present
disclosure. FIGS. 2B, 3B, 4B, 5B, 5D, and 6B are cross-sectional
diagrams of the workpiece 200 at various stages of the method 100
of fabricating the workpiece 200 according to various aspects of
the present disclosure. In particular, FIGS. 2B, 3B, 4B, 5B, 5D,
and 6B are cross-sections taken along line 202 of the corresponding
top-view diagrams.
[0015] Referring first to block 102 of FIG. 1 and to FIGS. 2A and
2B, a workpiece 200 is received that includes a substrate 204 that
is to undergo a fabrication process. The manufacture of integrated
circuits includes a wide array of fabrication processes including
implantation processes, etching processes, deposition processes,
and epitaxy processes, and any number of these processes and others
may be performed on the substrate 204. In order to selectively
process portions of the substrate 204, a resist and/or masking
materials may be deposited on the substrate and patterned to expose
only the portions to be processed (e.g., implanted, etched, etc.),
as explained in further detail below.
[0016] With respect to the substrate 204 itself, in various
examples, the substrate 204 comprises an elementary (single
element) semiconductor, such as silicon or germanium in a
crystalline structure; a compound semiconductor, such as silicon
germanium, silicon carbide, gallium arsenic, gallium phosphide,
indium phosphide, indium arsenide, and/or indium antimonide; a
non-semiconductor material, such as soda-lime glass, fused silica,
fused quartz, and/or calcium fluoride (CaF.sub.2); and/or
combinations thereof. The substrate 204 may include one or more
layers of varying composition, such as a Silicon-On-Insulator (SOI)
substrate 204 that includes a semiconductor layer disposed on an
insulator layer that is disposed on another semiconductor
layer.
[0017] Referring to block 104 of FIG. 1 and referring still to
FIGS. 2A and 2B, a resist 206 is formed on the substrate 204. The
resist 206 represents any resist material, and in many embodiments,
the resist 206 includes a photoresist material sensitive to
radiation such as UV light, deep ultraviolet (DUV) radiation,
and/or EUV radiation. However, the principles of the present
disclosure apply equally to e-beam resists and other direct-write
resist materials. The resist 206 may be applied by any suitable
technique, and an exemplary embodiment, the resist 206 is applied
in a liquid form using a spin coating (i.e., spin-on) technique.
Spin coating may use centrifugal force to disperse the resist 206
in a liquid form across the surface of the substrate 204 in a
substantially uniform thickness. To facilitate application, the
resist 206 may include a solvent, which when removed, leaves the
resist 206 in a solid or semisolid form. The solvent may be driven
off as part of the spin coating, during a settling process, and/or
during a post-application/pre-exposure baking (i.e., prebake)
process.
[0018] Regarding its composition, the resist 206 may include one or
more photosensitive materials. For example, the resist 206 may
include a photo-acid generator (PAG) that, as the name implies,
generates an acid within those portions of the resist 206 exposed
to radiation. A polymer within the resist 206, such as an
acid-cleavable polymer or acid-cross-linkable polymer, is sensitive
to this generated acid, causing the portion of the polymer in the
exposed regions to undergo a chemical reaction. The resist 206 may
also include a photobase generator (PBG) and/or photo-decomposable
quencher (PDQ) to reduce acid concentration in unexposed or
marginally-exposed regions of the resist 206 and thereby inhibit
the chemical reaction of the polymer in these regions. In some
embodiments, the resist 206 also includes one or more chromophores,
solvents, and/or surfactants.
[0019] Referring to block 106 of FIG. 1, a lithographic exposure is
performed on the workpiece 200 that exposes selected regions of the
resist 206 to radiation. Suitable radiation includes UV light, deep
ultraviolet (DUV) radiation, and/or EUV radiation. In further
examples, the selected regions are exposed to an e-beam or ion
beam. In these cases and others, the exposure of block 106 causes a
chemical reaction to occur in the exposed regions of the resist
206.
[0020] Referring to block 108 of FIG. 1 and to FIGS. 3A and 3B, a
developing process is performed on the workpiece 200 to form a
patterned resist 206. The developing process may begin with a
post-exposure bake. Following the post-exposure bake, a developer
is applied to the workpiece 200. The developer dissolves or
otherwise removes either the exposed regions in the case of a
positive resist development process or the unexposed regions in the
case of a negative resist development process. Suitable positive
developers include TMAH (tetramethyl ammonium hydroxide), KOH, and
NaOH, and suitable negative developers include solvents such as
n-butyl acetate, ethanol, hexane, benzene, and toluene.
[0021] After the developer is applied to the workpiece 200, the
patterned resist 206 may be rinsed, and a hard bake may be
performed on the workpiece 200 to further stabilize the pattern of
the resist 206.
[0022] The pattern of the resist 206 after developing may have any
suitable shape and structure and may include features of resist 206
separated by trenches 302. In some embodiments, the pattern is
governed by the stability of the resist 206, limitations of a
lithographic system used to pattern the resist 206, fabrication
processes to be performed using the resist 206, and/or other
factors. For example, capillary action and other forces may cause
the features of the resist 206 to collapse if a narrow trench is
formed between the features. Accordingly, in some such embodiments,
the pattern is structured to limit the ratio of trench height (as
indicated by marker 304) to trench width (as indicated by marker
306) to a particular threshold (e.g., a ratio of .ltoreq.10). The
particular threshold may depend on a number of factors including
resist stability and other properties of the resist 206, properties
of the substrate 204, and/or properties of a subsequent fabrication
processes that may induce the resist 206 to collapse, such as
processing temperature.
[0023] While the ratio threshold may seem to imply that a narrower
trench may be formed by simply thinning the resist 206, in some
applications, a fabrication process that follows relies on a
particular minimum thickness of the resist 206. For example, an ion
implantation process may rely on the resist 206 having at least a
minimum thickness to block the ions from reaching the substrate
204. Likewise, an etching process may rely on the resist 206 having
at least a minimum thickness to withstand an etchant long enough to
etch the exposed portions of the substrate 204.
[0024] Accordingly, to produce a narrow aspect ratio, in some
embodiments, a wider trench is formed and then narrowed by
conformally depositing a material within the trench. Referring to
block 110 of FIG. 1 and to FIGS. 4A and 4B, a dielectric material
402 is deposited on the developed resist 206 and within the
trenches 302 between the features of the resist 206. The dielectric
material 402 may include a semiconductor oxide, a semiconductor
nitride, a semiconductor oxynitride, a semiconductor carbide,
and/or other suitable insulator materials, and may be formed to any
suitable thickness. In some examples, the dielectric material 402
includes silicon oxide and is formed to a vertical thickness 404
and a horizontal vertical thickness 406 of between about 50 nm and
about 100 nm. The dielectric material 402 may be deposited
conformally such that the vertical thickness 404 and horizontal
vertical thickness 406 are substantially equivalent, or
non-conformally. As can be seen, forming the dielectric material
402 with a given thickness in a trench reduces the width of the
trench by about twice the horizontal thickness 406 of the
dielectric material 402. Thus, in some embodiments, the deposition
of the dielectric material 402 allows for forming trenches with a
height/width ratio greater than using the resist 206 alone. In one
such embodiment, deposition of the dielectric material 402 creates
suitable trenches 302 with a ratio of trench height to trench width
that is .gtoreq.13.
[0025] The dielectric material 402 may be deposited using any
suitable technique. In some examples, the dielectric material 402
is deposited using a catalyst deposition process such as Catalyst
Enhanced Chemical Vapor Deposition (CECVD). In some examples, the
dielectric material 402 is deposited using Plasma Enhanced CVD
(PECVD). The deposition technique may be tuned to produce any
suitable deposition rate, and in various examples, the deposition
rate for the dielectric material 402 is between about 1 .ANG. and
about 10 .ANG. per minute. The deposition process may be performed
at any suitable temperature. In some examples, the dielectric
material 402 is deposited at a temperature between about 50.degree.
C. and about 100.degree. C. or between about room temperature
(-20.degree. C.) and about 100.degree. C. Regarding the lower
bound, these ranges have been determined to be sufficiently warm to
promote deposition of the dielectric material 402, which may be
inhibited by temperatures below these ranges. Regarding the upper
bound, some resist 206 materials deform at deposition temperatures
exceeding 100.degree. C. Accordingly, performing deposition at the
above temperature ranges allows the dielectric material 402 to be
deposited without risk to the resist 206 material.
[0026] Referring to block 112 of FIG. 1 and to FIGS. 5A, 5B, 5C,
and 5D, a fabrication process is performed on the workpiece 200.
The fabrication process may be any suitable process and may utilize
the patterned resist 206 to processes exposed portions of the
substrate 204 differently from those portions covered by the resist
206. For example, the fabrication process may include an ion
implantation process to form a junction isolation structure 502 in
the substrate 204. The junction isolation structure 502 is suitable
to isolate pixel regions 504 of an image sensor or devices of other
integrated circuits. A junction isolation structure 502 isolates
circuit elements by creating a reverse biased p-n junction between
the elements. Accordingly, the implantation process may implant
ions of p-type dopants, such as boron or BF.sub.2, into a substrate
204 that contains n-type dopants, such as phosphorus or arsenic, or
may implant ions of n-type dopants into a substrate 204 that
contains p-type dopants.
[0027] The implantation process may be performed using any suitable
implantation energy, and the thickness and composition of the
resist 206 and the dielectric material 402 may be configured such
that the ions have sufficient energy that they are implanted
through the single thickness of the dielectric material 402 at the
bottom of the trench 302 but not enough to implant through the
resist 206 or through the dielectric material 402 on the sidewalls
of the trench 302. Additionally or in the alternative, the
dielectric material 402 at the bottom of the trench 302 may be
removed prior to the implantation. Referring to FIGS. 5A and 5B, in
an example, an anisotropic (directional) etching is performed to
remove the dielectric material 402 from the bottom of the trench
302 while leaving the dielectric material 402 on the side surfaces
of the resist 206. The anisotropic etching may also remove the
dielectric material 402 from the top surface of the resist 206. Any
suitable anisotropic etching technique may be used such as a dry or
plasma etching technique. With the dielectric material 402 removed
from the bottom of the trench 302, the above implantation process
may be performed on the substrate 204 with enough implantation
energy to form the junction isolation structure 502 but not enough
to implant through the resist 206 or through the dielectric
material 402 on the sidewalls of the trench 302, as shown in FIGS.
5C and 5D.
[0028] In further embodiments, the fabrication process includes an
ion implantation process to produce other types of features such as
source/drain regions. In yet further embodiments, the fabrication
process of block 112 includes etching processes, deposition
processes, epitaxy processes, and/or other suitable processes. In
these embodiments and others, the patterned resist 206 and
dielectric material 402 are used to fabricate a gate stack, to
fabricate an interconnect structure, to form non-planar devices by
etching to expose a fin or by epitaxially growing fin material,
and/or to form other suitable features.
[0029] Referring to block 114 of FIG. 1 and to FIGS. 6A and 6B, the
dielectric material 402 is removed and the resist 206 is stripped.
These materials may be removed by any suitable etching and/or
stripping technique such as dry etching, wet etching, and/or other
etching methods (e.g., Reactive Ion Etching (RIE), Chemical
Mechanical Polishing/Planarization (CMP), etc.), and the dielectric
material 402 and resist 206 may be removed concurrently or in
multiple steps with different chemistries targeting different
materials.
[0030] Referring to block 116, the workpiece 200 is provided for
further fabrication processes. For example, the workpiece 200 may
be used to fabricate an image sensor, other integrated circuit
chip, a System-On-a-Chip (SOC), and/or a portion thereof, and thus
the subsequent fabrication processes may form various passive and
active microelectronic devices such as sensors, resistors,
capacitors, inductors, diodes, Metal-Oxide Semiconductor Field
Effect Transistors (MOSFET), Complementary Metal-Oxide
Semiconductor (CMOS) transistors, Bipolar Junction Transistors
(BJT), Laterally Diffused MOS (LDMOS) transistors, high power MOS
transistors, other types of transistors, and/or other circuit
elements.
[0031] Further examples of the technique are described with
reference to FIGS. 7A-22B. In that regard, FIGS. 7A and 7B are flow
diagrams of a method 700 of fabricating a workpiece using
orthogonal features according to various aspects of the present
disclosure. Additional steps can be provided before, during, and
after the method 700, and some of the steps described can be
replaced or eliminated for other embodiments of the method 700.
FIGS. 8A, 9A, 10A, 11A, 12A, 13A, 14A, 15A, 16A, 17A, 18A, 19A,
20A, 21A, and 22A are top-view diagrams of the workpiece 800 at
various stages of the method 700 of fabricating the workpiece 800
according to various aspects of the present disclosure. FIGS. 8B,
9B, 10B, 11B, 12B, 13B, 14B, 15B, 16B, 17B, 18B, 19B, 20B, 21B, and
22B are cross-sectional diagrams of the workpiece 800 at various
stages of the method 700 of fabricating the workpiece 800 according
to various aspects of the present disclosure. In particular, FIGS.
8B, 9B, 10B, 11B, 12B, 13B, and 14B are cross-sections taken along
line 802 of the corresponding top-view diagrams, while FIGS. 15B,
16B, 17B, 18B, 19B, 20B, 21B, and 22B are cross-sections taken
along line 1502 of the corresponding top-view diagrams.
[0032] In contrast to some of the above examples, method 700
divides an area of the workpiece 800 into orthogonal sets of
parallel stripes. Stripes running in a first direction are
fabricated first, and perpendicular stripes are fabricated
thereafter.
[0033] Referring first to block 702 of FIG. 7A and to FIGS. 8A and
8B, a workpiece 800 is received that includes a substrate 804 that
is to undergo a fabrication process. The substrate 804 may be
substantially similar to the substrate 204 of FIGS. 2A-6B. In
various examples, the substrate 804 includes an elementary (single
element) semiconductor, a compound semiconductor, a
non-semiconductor material, and/or combinations thereof.
[0034] Referring to block 704 of FIG. 7A, a first resist 804 is
applied to the substrate. This may be performed substantially as
described in block 104 of FIG. 1. The first resist 804 may be
substantially similar to the resist 206 of FIGS. 2A-6B. In various
examples, the first resist 804 includes a photoresist material, an
e-beam resist material, and/or other suitable resist material and
is applied by spin coating or other suitable technique.
[0035] Referring to block 706 of FIG. 7A, a lithographic exposure
is performed on the workpiece 800 that exposes selected regions of
the first resist 804 to radiation. This may be performed
substantially as described in block 106 of FIG. 1.
[0036] Referring to block 708 of FIG. 7A and to FIGS. 9A and 9B, a
developing process is performed on the workpiece 800 to form a
patterned first resist 804. This may be performed substantially as
described in block 108 of FIG. 1. The developing process may begin
with a post-exposure bake. Following the post-exposure bake, a
developer is applied to the workpiece 800. The developer dissolves
or otherwise removes either the exposed regions of the first resist
804 in the case of a positive resist development process or the
unexposed regions of the first resist 804 in the case of a negative
resist development process. After the developer is applied to the
workpiece 800, the patterned first resist 804 may be rinsed, and a
hard bake may be performed on the workpiece 800 to further
stabilize the pattern of the first resist 804.
[0037] The pattern of the resist 804 after developing may have any
suitable shape and structure. In some embodiments, the pattern is
governed by the stability of the resist 804, limitations of a
lithographic system used to pattern the resist 804, fabrication
processes to be performed using the resist 804, and/or other
factors. In some examples, the patterned resist includes sets of
substantially parallel features of the first resist 804 extending
in a first direction 902. The features of the first resist 804 may
have any suitable aspect ratio, and in some such embodiments, the
pattern is structured to limit the ratio of trench height (as
indicated by marker 904) to trench width (as indicated by marker
906) to a particular threshold (e.g., a ratio of .ltoreq.5).
[0038] Referring to block 710 of FIG. 7A and to FIGS. 10A and 10B,
a first dielectric material 1002 is deposited on the patterned
first resist 804 and particularly on the side surfaces of the
resist 804. This may be performed substantially as described in
block 110 of FIG. 1. The first dielectric material 1002 may be
substantially similar to the dielectric material 402 of FIGS.
4A-6B. The first dielectric material 1002 may include a
semiconductor oxide, a semiconductor nitride, a semiconductor
oxynitride, a semiconductor carbide, and/or other suitable
insulator materials, and may be formed to any suitable thickness.
The first dielectric material 1002 may be selected to have a
different etchant sensitivity than the first resist 804. In some
examples, the first dielectric material 1002 includes silicon oxide
and is formed to a thickness 1004 of between about 20 nm and about
50 nm.
[0039] The first dielectric material 1002 may be deposited by any
suitable technique or combination of techniques such as CECVD
and/or PECVD. In some examples, the first dielectric material 1002
is deposited at a temperature between about 50.degree. C. and about
100.degree. C. or between about room temperature (-20.degree. C.)
and about 100.degree. C. These ranges have been determined to be
sufficiently warm to promote deposition of the dielectric material
1002 without risk of deforming the first resist 806. In contrast,
deposition temperatures below these ranges may not allow proper
deposition, and deposition temperatures above these ranges may
cause the first resist 806 to deform.
[0040] Referring to block 712 of FIG. 7A and to FIGS. 11A and 11B,
a second resist 1102 is deposited on the first resist 804 and the
first dielectric material 1002. The second resist 1102 may be
substantially similar to the first resist 804 and may include a
photoresist material, an e-beam resist material, and/or other
suitable resist material. Alternately, the second resist 1102 may
be a lithographically inert dielectric (e.g., some spin-on
dielectrics) or other suitable resist material. In some
embodiments, the second resist 1102 is selected to have different
etchant sensitivity than the first dielectric material 1002.
[0041] The second resist 1102 may be applied by any suitable
technique, such as spin coating, and may be cured using heat,
radiation, e-beam exposure, and/or plasma exposure. In embodiments
where the second resist 1102 includes a photoresist material, the
second resist 1102 may be exposed using a flood exposure to
stabilize the photosensitive components.
[0042] Referring to block 714 of FIG. 7A and to FIGS. 12A and 12B,
the second resist 1102 is planarized to expose the first dielectric
material 1002. This may be performed by any suitable technique, and
in some examples, the second resist 1102 is planarized by a CMP
process. In addition to the second resist 1102, the CMP process may
planarize the first resist 804 and the first dielectric material
1002. By exposing the first dielectric material 1002, the
planarization creates features of the first resist 804 and features
of the second resist 1102 separated by the first dielectric
material 1002.
[0043] The planarization of block 714 exposes the vertical channels
of the first dielectric material 1002, and referring to block 716
of FIG. 7A and to FIGS. 13A and 13B, the vertical channels of the
first dielectric material 1002 are selectively removed by an
etching process such as dry etching, wet etching, and/or other
etching methods. The etchant chemistries, temperature, duration,
and other parameters may be configured to spare the first resist
804 and the second resist 1102 from significant etching. The
removal of the first dielectric material 1002 leaves trenches 1302
extending in the first direction 902 between the features of the
first resist 804 and the features of the second resist 1102. The
trenches 1302 formed by the removal of the first dielectric
material 1002 may be significantly narrower than those formed using
resist material(s) alone, and in some embodiments, the ratio of
trench height to trench width exceeds 50.
[0044] Referring to block 718 of FIG. 7A and to FIGS. 14A and 14B,
a fabrication process is performed on the workpiece 800. This may
be performed substantially as described in block 112 of FIG. 1. The
fabrication process may be any suitable process and may utilize the
patterned resists to processes exposed portions of the substrate
804 differently from those portions covered by the first resist 804
and second resist 1102. For example, the fabrication process may
include an ion implantation process to form a junction isolation
structure 1402 in the substrate 804, other ion implantation
processes, etching processes, deposition processes, epitaxy
processes, and/or other suitable processes.
[0045] Referring to block 720 of FIG. 7A, any remaining portion of
the first resist 804, the second resist 1102, and/or the first
dielectric material 1002 is removed. This may be performed
substantially as described in block 114 of FIG. 1. These materials
may be removed by any suitable etching and/or stripping technique
such as dry etching, wet etching, and/or other etching methods.
[0046] As the process of blocks 704-720 may be performed on stripes
of the substrate 804 running in the first direction 902, in some
embodiments, the processes are then repeated in a second direction
1504 perpendicular to the first. Referring to block 722 of FIG. 7B
and to FIGS. 15A and 15B, a third resist 1506 is applied to the
substrate. This may be performed substantially as described in
block 704 of FIG. 7A, and the third resist 1506 may be
substantially similar to the first resist 804 and/or the second
resist 1102. In various examples, the third resist 1506 includes a
photoresist material, an e-beam resist material, and/or other
suitable resist material and is applied using by spin coating or
other suitable technique.
[0047] Referring to block 724 of FIG. 7B, a lithographic exposure
is performed on the workpiece 800 that exposes selected regions of
the third resist 1506 to radiation, and referring to block 726 of
FIG. 7B and to FIGS. 16A and 16B, a developing process is performed
on the workpiece 800. This may be performed substantially as
described in blocks 706 and 708, respectively. The developing
process may begin with a post-exposure bake. Following the
post-exposure bake, a developer is applied to the workpiece 800.
The developer dissolves or otherwise removes either the exposed
regions of the third resist 1506 in the case of a positive resist
development process or the unexposed regions of the third resist
1506 in the case of a negative resist development process. After
the developer is applied to the workpiece 800, the patterned third
resist 1506 may be rinsed, and a hard bake may be performed on the
workpiece 800 to further stabilize the pattern of the resist
1506.
[0048] The pattern of the third resist 1506 after developing may
have any suitable shape and structure. In some embodiments, the
pattern is governed by the stability of the third resist 1506, by
limitations of a lithographic system used to pattern the third
resist 1506, by the fabrication process to be performed using the
patterned third resist 1506, and/or by other factors. In some
examples, the patterned resist includes sets of substantially
parallel features of the third resist 1506 extending in a second
direction 1504 substantially perpendicular to the previous features
of the first resist 804.
[0049] Referring to block 728 of FIG. 7B and to FIGS. 17A and 17B,
a second dielectric material 1702 is deposited on the developed
third resist 1506 and particularly on the side surfaces of the
resist 1506. This may be performed substantially as described in
block 710 of FIG. 7A. The second dielectric material 1702 may be
substantially similar to the first dielectric material 1002 and may
include a semiconductor oxide, a semiconductor nitride, a
semiconductor oxynitride, a semiconductor carbide, and/or other
suitable insulator materials. The second dielectric material 1702
may be selected to have a different etchant sensitivity than the
third resist 1506 and may be formed to any suitable thickness. In
some examples, the second dielectric material 1702 includes silicon
oxide and is formed to a thickness 1704 of between about 20 nm and
about 50 nm.
[0050] The second dielectric material 1702 may be deposited by any
suitable technique or combination of techniques such as CECVD
and/or PECVD. In some examples, the second dielectric material 1702
is deposited at a temperature between about 50.degree. C. and about
100.degree. C. or between about room temperature (-20.degree. C.)
and about 100.degree. C. These ranges have been determined to be
sufficiently warm to promote deposition of the second dielectric
material 1702 without risk of deforming the third resist 1506. In
contrast, deposition temperatures below these ranges may not allow
proper deposition, and deposition temperatures above these ranges
may cause the third resist 1506 to deform.
[0051] Referring to block 730 of FIG. 7B and to FIGS. 18A and 18B,
a fourth resist 1802 is deposited on the third resist 1506 and the
second dielectric material 1702. The fourth resist 1802 may be
substantially similar to the third resist 1506 and may include a
photoresist material, an e-beam resist material, and/or other
suitable resist material. Alternately, the fourth resist 1802 may
be a lithographically inert dielectric (e.g., some spin-on
dielectrics) or other suitable resist material. In some
embodiments, the fourth resist 1802 is selected to have different
etchant sensitivity than the second dielectric material 1702.
[0052] The fourth resist 1802 may be applied by any suitable
technique, such as spin coating, and may be cured using heat,
radiation, e-beam exposure, and/or plasma exposure. In embodiments
where the fourth resist 1802 includes a photoresist material, the
fourth resist 1802 may be exposed using a flood exposure to
stabilize the photosensitive components.
[0053] Referring to block 732 of FIG. 7B and to FIGS. 19A and 19B,
the fourth resist 1802 is planarized to expose the second
dielectric material 1702. This may be performed substantially as
described in block 714 of FIG. 7A, and in some examples, the fourth
resist 1802 is planarized by a CMP process. In addition to the
fourth resist 1802, the CMP process may planarize the third resist
1506 and the second dielectric material 1702. By exposing the
second dielectric material 1702, the planarization creates features
of the third resist 1506 and features of the fourth resist 1802
separated by the second dielectric material 1702.
[0054] The planarization of block 732 exposes the vertical channels
of the second dielectric material 1702, and referring to block 734
of FIG. 7B and to FIGS. 20A and 20B, the vertical channels of the
second dielectric material 1702 are selectively removed by an
etching process such as dry etching, wet etching, and/or other
etching methods. The etchant chemistries, temperature, duration,
and other parameters may be configured to spare the third resist
1506 and the fourth resist 1802 from significant etching. The
removal of the first dielectric material 1002 leaves trenches 2002
extending in the second direction 1504 between the third resist
1506 and the fourth resist 1802. The trenches 2002 formed by the
removal of the second dielectric material 1702 may be significantly
narrower than those formed using resist material(s) alone, and in
some embodiments, the ratio of trench height to trench width
exceeds 50.
[0055] Referring to block 736 of FIG. 7B and to FIGS. 21A and 22B,
a fabrication process is performed on the workpiece 800. This may
be performed substantially as described in block 718 of FIG. 7A.
The fabrication process may be any suitable process and may utilize
the patterned resists to processes exposed portions of the
substrate 804 differently from those portions covered by the third
resist 1506 and fourth resist 1802. For example, the fabrication
process may include an ion implantation process to further form a
junction isolation structure 1402 in the substrate 804, other ion
implantation processes, etching processes, deposition processes,
epitaxy processes, and/or other suitable processes.
[0056] Referring to block 738 of FIG. 7B and to FIGS. 22A and 22B,
any remaining portion of the third resist 1506, the fourth resist
1802, and/or the second dielectric material 1702 is removed. This
may be performed substantially as described in block 720 of FIG. 7.
These materials may be removed by any suitable etching and/or
stripping technique such as dry etching, wet etching, and/or other
etching methods.
[0057] Referring to block 740, the workpiece 800 is provided for
further fabrication processes. For example, the workpiece 800 may
be used to fabricate an image sensor, other integrated circuit
chip, a system on a chip (SOC), and/or a portion thereof, and thus
the subsequent fabrication processes may form various passive and
active microelectronic devices such as sensors, resistors,
capacitors, inductors, diodes, metal-oxide semiconductor field
effect transistors (MOSFET), complementary metal-oxide
semiconductor (CMOS) transistors, bipolar junction transistors
(BJT), laterally diffused MOS (LDMOS) transistors, high power MOS
transistors, other types of transistors, and/or other circuit
elements.
[0058] Thus, the present disclosure provides examples of forming a
pattern for integrated circuit fabrication. In some examples, a
method includes receiving a substrate. A patterned resist is formed
on the substrate and has a trench defined therein. A dielectric
material is deposited on the patterned resist and within the trench
such that the dielectric narrows a width of the trench to further
define the trench. A fabrication process is performed on a region
of the substrate underlying the trench defined by the dielectric.
In some such examples, the fabrication process includes an
ion-implantation process, and a thickness of the dielectric at a
bottom of the trench permits the ion-implantation process to
implant the region of the substrate through the dielectric. In some
such examples, the ion-implantation process forms a junction
isolation region within the substrate. In some such examples, the
junction isolation region isolates a set of pixel regions of an
image sensor. In some such examples, the depositing of the
dielectric is performed at a temperature between about 20.degree.
C. and about 100.degree. C. In some such examples, the depositing
of the dielectric includes a technique from a group consisting of
catalyst enhanced chemical vapor deposition and plasma enhanced
chemical vapor deposition. In some such examples, the depositing of
the dielectric is configured to deposit the dielectric
substantially conformally within the trench. In some such examples,
the trench having the narrowed width has a height-to-width ratio of
greater than or equal to 13. In some such examples, the trench
prior to the depositing of the dielectric has a height-to-width
ratio of less than or equal to 10.
[0059] In further examples, a method includes receiving a substrate
and depositing a resist material on the substrate. The resist
material is patterned to form a first feature and a second feature
with a trench disposed therebetween. A dielectric is deposited
within the trench, and a fabrication process is performed on the
substrate using the trench having the dielectric deposited therein.
In some such examples, the fabrication process is performed on a
first region of the substrate, and the resist and a first portion
of the dielectric on a sidewall of the trench are configured to
protect a second region of the substrate from the fabrication
process. In some such examples, the fabrication process includes an
ion-implantation process, and a second portion of the dielectric on
a bottom of the trench above the first region of the substrate is
configured to implant the first region of the substrate through the
dielectric. In some such examples, the fabrication process includes
an ion-implantation process, and the ion-implantation process forms
a junction isolation region within the substrate. In some such
examples, the junction isolation region isolates a set of pixel
regions of an image sensor. In some such examples, the depositing
of the dielectric is performed at a temperature between about
20.degree. C. and about 100.degree. C. In some such examples, the
depositing of the dielectric includes a technique from a group
consisting of catalyst enhanced chemical vapor deposition and
plasma enhanced chemical vapor deposition. In some such examples,
the trench after the depositing of the dielectric has a
height-to-width ratio of greater than or equal to 13.
[0060] In yet further examples, a method includes receiving a
substrate, and patterning a first resist on the substrate to form a
first feature. A dielectric is deposited on a side surface of the
first feature, and a second resist is deposited on the substrate to
form a second feature separated from the first feature by the
dielectric. The dielectric is selectively removed to form a trench
between the first feature and the second feature, and the substrate
exposed by the trench is selectively processed. In some such
examples, the dielectric is a first dielectric, the trench is a
first trench, and the first trench extends in a first direction. A
third resist on the substrate is patterned to form a third feature.
A second dielectric is deposited on a side surface of the third
feature, and a fourth resist is deposited on the substrate to form
a fourth feature separated from the third feature by the second
dielectric. The second dielectric is selectively removed to form a
second trench between the third feature and the fourth feature that
extends in a second direction substantially perpendicular to the
first direction. The substrate exposed by the second trench is
selectively processed. In some such examples, the processing of the
substrate exposed by the trench includes an ion implantation to
form a junction isolation region within the substrate.
[0061] 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.
* * * * *