Semiconductor device manufacturing: process – Chemical etching – Vapor phase etching
Reexamination Certificate
2001-08-13
2003-05-06
Smith, Matthew (Department: 2825)
Semiconductor device manufacturing: process
Chemical etching
Vapor phase etching
C438S687000
Reexamination Certificate
active
06559061
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to semiconductor device metal layer interconnects and more particularly to reducing the contact resistance of interconnects.
BACKGROUND OF THE INVENTION
A typical integrated circuit contains a plurality of metal pathways to provide electrical power for powering the various semiconductor devices comprising the integrated circuit, and to allow these semiconductor devices to share/exchange electrical information. Within integrated circuits, metal layers are stacked on top of one another by using intermetal or “interlayer” dielectrics that insulate the metal layers from each other. Typically, however, each metal layer must form electrical contact to an additional metal layer. Metal-layer-to-metal-layer electrical contact is achieved by etching a hole (i.e., a via) in the interlayer dielectric that separates the first and second metal layers, and by filling the resulting hole or via with a metal to create an interconnect as described further below.
The use of copper in place of aluminum as the interconnect material for semiconductor devices has grown in popularity due to copper's lower resistivity. Unlike aluminum, however, copper is highly mobile in silicon dioxide and may, as a result of infiltration of copper atoms into the dielectric, create leakage paths through a device's various dielectric layers. Copper atoms also can cause electrical defects in silicon. Accordingly, as best understood with reference to
FIGS. 1A-1C
described below, a semiconductor device employing copper interconnects requires the creation of encapsulating barrier layers to prevent deleterious incorporation of copper atoms into the device's various material layers.
FIGS. 1A-C
show sequential cross-sectional views of the formation of a conventional copper interconnect
10
(
FIG. 1C
) through an aperture in a dielectric layer disposed between two copper layers, a first copper layer
11
a
disposed within a dielectric layer D and a second copper layer
11
b
. With reference to
FIG. 1A
, to form the copper interconnect
10
, a silicon dioxide interlayer dielectric
13
is deposited over the first copper layer
11
a
. A first via
15
then is etched in the interlayer dielectric
13
to expose the first copper layer
11
a.
Copper is highly reactive with oxygen and easily forms a surface layer of high resistivity copper oxide when exposed to an oxygen rich atmosphere. Because the first layer
11
a
is copper, a high resistance copper oxide layer
11
a
′ can form on the top surface of the first copper layer
11
a
if the first copper layer
11
a
is exposed to oxygen or water vapor (e.g., air). This oxidation can occur when the wafers, just having the vias etched therein, are moved from an etch tool to a metallization tool. The copper oxide layer
11
a
will complete formation once all exposed and unoxidized copper is converted to copper oxide. Accordingly, to minimize the resistance of the copper interconnect
10
, the copper oxide layer
11
a
′ must be removed. Typically the copper oxide layer
11
a
′ is removed by sputtering the copper oxide layer
11
a
′ with ions generated within a plasma (i.e., sputter-etching), such as argon ions generated within an argon plasma. The argon ions are accelerated toward the wafer via a negative electric bias imposed on the wafer or on the wafer support. These ions strike the wafer and the copper oxide layer
11
a
′ at the base of the unfilled via, and eject material from the copper oxide layer
11
a
′ (including copper immediately beneath the copper oxide) due to momentum transfer between the accelerated argon ions and the copper oxide layer
11
a′.
The ejected material, which includes copper atoms
11
a
″, coats the interlayer dielectric
13
as shown in FIG.
1
A. The copper atoms
11
a
″ contained in the ejected material can enter the interlayer dielectric
13
and drift therethrough under the influence of an applied electric field (e.g., a device voltage), causing deleterious interconnect-to-interconnect leakage currents (i.e., via-to-via leakage currents). Such deleterious via-to-via leakage currents, however, cannot be avoided in conventional copper interconnects if the copper oxide layer
11
a
′ is removed. Accordingly, conventional copper interconnects suffer from either a high resistance copper oxide layer
11
a
′ which is left in place to prevent dielectric degradation induced by copper sputtered directly on the wall of the unfilled via, or copper atom induced degradation in the dielectric which leads to via-to-via leakage currents.
Following removal of the copper oxide layer
11
a
′, a thin barrier layer
17
(e.g., tantalum, tantalum nitride, titanium nitride, tungsten or tungsten nitride) is deposited over the interlayer dielectric
13
and the first copper layer
11
a
as shown in FIG.
1
B. The barrier layer
17
prevents copper atoms from a subsequently deposited copper layer (namely the second copper layer
11
b
of
FIG. 1C
) from incorporating into, and thus degrading, the interlayer dielectric
13
.
To complete the conventional copper interconnect
10
, the second copper layer lib is deposited over the barrier layer
17
either conformally or in the form of a copper plug
11
b
′, as shown in
FIG. 1C. A
copper “seed” layer (not shown) typically is deposited prior to deposition of the copper plug
11
b
′. Thus, a conventional copper interconnect
10
consists of the first copper layer
11
a
“in contact” with the second copper layer
11
b
through the barrier layer
17
.
Because the barrier layer
17
can have a resistivity up to 100 times greater than the resistivity of copper, the barrier layer
17
significantly increases the contact resistance of the interconnect
10
formed between the first copper layer
11
a
and the second copper layer
11
b
. Therefore, the significant advantage of copper's lower resistivity is not fully realized due to the presence of barrier layers. The barrier layer
17
, however, is required to prevent further incorporation of copper atoms within the interlayer dielectric
13
.
In sum, conventional copper interconnects suffer from high resistances due to the presence of barrier layers, and can suffer from via-to-via leakage currents due to sputtered copper atom incorporation in the interlayer dielectric
13
during interconnect formation. Accordingly, a need exists for an improved copper interconnect that does not suffer from either high resistance or via-to-via leakage currents.
SUMMARY OF THE INVENTION
The present invention provides an inventive copper interconnect free from copper atom via-to-via leakage current paths and preferably having a significantly reduced resistance. Specifically, in a first aspect, a barrier layer (e.g., tantalum, tantalum nitride, titanium nitride, tungsten or tungsten nitride) is deposited on the exposed first copper layer and on the interlayer dielectric prior to sputter-etching the copper oxide layer. Thereafter, the barrier layer at the bottom of the interlayer dielectric's via, and the copper oxide layer thereunder, are sputter-etched. Because the barrier layer is deposited prior to sputter-etching, during sputter-etching copper atoms from the copper oxide layer redistribute on the barrier layer rather than on the interlayer dielectric. The copper atoms are not mobile within the barrier layer, and are prevented from diffusing to and contaminating the interlayer dielectric. Accordingly, no via-to-via leakage current paths are created during copper interconnection formation.
Following sputter-etching, the second copper layer is deposited over the barrier layer and the exposed first copper layer to complete copper interconnect formation. Because the first and second copper layers are in direct contact, the high resistivity of the barrier layer is eliminated. Accordingly, the inventive copper interconnect has low resistance in addition to no via-to-via leakage current paths.
In a second aspect, a capping dielectric barrier layer (e
Chiang Tony
Chin Barry
Hashim Imran
Applied Materials Inc.
Dugan & Dugan
Lee Calvin
Smith Matthew
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