The present invention relates to a method of fabricating a semiconductor device. More specifically, the invention relates to a method of fabricating electrical contacts for a semiconductor device such as a memory device.
Complex integrated electronic devices like DRAM memory devices comprise a plurality of conductive layers that are electrically insulated from one another and are disposed in different layer levels or depths having different distances to the substrate's surface. Accordingly, fabricating contacts requires etching contact holes down to the buried conductive layers. However, this is usually quite time-consuming as each contact layer may require a separate handling due to the fact that the depths of the conductive layers may differ considerably.
One aspect of the present invention provides a method of fabricating a semiconductor device that allows contacting a plurality of contact pads belonging to different buried conductive layers at the same time.
Another aspect of the present invention avoids damages of the buried conductive layers during etching of the contact holes.
According to embodiments of the present invention, fabricating a semiconductor device includes fabricating a first conductive layer including a first contact pad and covering the first conductive layer with a first protection layer at least on top of the first contact pad such that a first protective cap is formed thereon. A second conductive layer including a second contact pad is fabricated, wherein the second conductive layer and the first conductive layer are electrically insulated from one another. The second conductive layer is covered with a second protection layer at least on top of the second contact pad such that a second protective cap is formed thereon. At least one intermediate layer is deposited on top of the structure. A mask is formed on top of the intermediate layer and the intermediate layer is etched thereby exposing the first protective cap and the second protective cap, wherein an etchant is applied that provides a larger etch rate with regard to the intermediate layer than with regard to the protective layer. After exposing the first and second protective caps, the first and second contact pads are etched and exposed during the same etch step.
According to embodiments of the invention, each contact pad of the conductive layers is individually protected by a protective cap. When electrical contacts are provided for the buried contact pads, contact holes are etched in a two-step-manner. In a first step, the intermediate layers on top of each protective cap are removed. Then, after exposing the protective caps (i.e., in a second step), the caps are removed and the buried contact pads are exposed. Therefore, according to embodiments of the invention, a plurality of contact pads belonging to different conductive layers in different depths may be exposed and subjected to metallization at the same time. This allows using a single etch mask for providing contacts to differently deep contact pads. Additionally, the removal of the protective caps proceeds in an identical manner for all pads independently of their individual depth. Therefore, damages of buried contact pads due to any sort of overetching are avoided.
According to a preferred embodiment of the invention, the first protection layer and the second protection layer may be fabricated simultaneously during the same fabrication step.
Alternatively, the semiconductor device is fabricated in or on a substrate such that the first conductive layer and the second conductive layer have different distances relative to the substrate's surface.
The first conductive layer may be fabricated inside the substrate below the substrate's surface. The second conductive layer may be fabricated above the substrate's surface.
Preferably the semiconductor device is a memory device comprising an array part with a plurality of memory cells. The first conductive layer may form a buried word line of the memory device and the first contact pad may form a buried word line contact pad. The second conductive layer may form a bit line of the memory device and the second contact pad may form a bit line contact pad.
Usually memory devices comprise a driving circuit being placed in a peripheral part of the devices located outside the array part. In this case, it is preferred that the second conductive layer simultaneously forms a gate contact layer of at least one transistor of the driving circuit.
In the latter case the method may further include covering the second conductive layer with the second protection layer also on top of the gate contact pad such that an additional protective cap is formed thereon; etching the intermediate layer and exposing the first protective cap, the second protective cap and the additional protective cap during the same etch step; and after exposing the protective caps, etching all of them and exposing all contact pads during the same etch step.
With regard to the driving circuit, it is further considered advantageous if the method includes fabricating a third conductive layer including source and drain contact pads for the at least one transistor of the driving circuit; and covering the third conductive layer with a third protection layer at least on top of the source and drain contact pads such that third protective caps are formed thereon.
The third conductive layer may be fabricated such that the upper surface of the third conductive layer is located further apart from the substrate's surface than the upper surface of the first and second conductive layers.
Preferably the method further includes depositing the intermediate layer on top of the third protection layer; structuring the intermediate layer and exposing the first protective cap, the second protective cap, the additional protective cap and both third protective caps during the same etch step; and after exposing the protective caps, etching all of them and exposing all underlying contact pads during the same etch step.
The source and drain contacts of at least one transistor of the driving circuit may be fabricated in a self-aligned fashion using a sacrificial layer consisting of or containing polysilicon, amorphous silicon, SiGe-material and/or carbon.
According to an alternative embodiment of the invention, the method includes etching the second protective layer using an etch mask and exposing the gate contact pad at least partly before the third conductive layer is fabricated enabling the third conductive layer to be located directly above and in contact with the exposed gate contact pad; and covering the third conductive layer with the third protection layer also at least on top of the gate contact pad.
The third protection layer and the underlying third conductive layer may be etched such that the gate contact pad, the source contact pad and the drain contact pad are electrically separated from another before depositing the intermediate layer. After depositing the intermediate layer this layer is preferably etched using an etch mask exposing the first protective cap, the second protective cap, the additional protective cap and both third protective caps during the same etch step; and after exposing the protective caps, they are etched and all underlying contact pads are exposed during the same etch step.
Preferably, the first protection layer and the second protection layer are fabricated simultaneously and the third protection layer is fabricated thereafter. The first protective layer, the second protective layer and the third protective layer may consist of or contain silicon nitride; and the intermediate layer may consist of or contain silicon oxide.
In order that the manner in which the above-recited and other advantages and aspects of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered to be limiting its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The following list of reference symbols can be used in conjunction with the figures:
Usually, the active area lines 15 are defined by forming isolation trenches 20 which are filled with an insulating material, in a semiconductor substrate such as a silicon substrate. Accordingly, the active area lines 15 are separated and electrically insulated from each other. At an intersection of an active area line 15 and a bit line 5, a bit line connection 25 is formed. Moreover, node connections 30 are formed at those portions of the active area lines 15 that are not covered by a bit line 5 nor by a word line 10. The node connections 30 provide an electrical contact between an access transistor and a corresponding storage capacitor. Usually, the storage capacitor is formed on top of the shown semiconductor surface.
As shown in
Transistors are formed in the active area lines 15, wherein the transistors comprise a first source/drain region, a second source/drain region as well as a channel connecting first and second source/drain regions. The conductivity of the channel between the first and the second source/drain regions is controlled by the word lines 10 and the isolation gate line 35. In particular, an appropriate voltage is applied to the isolation gate line 35, so that no current flows beneath the isolation gate line. Accordingly, an electrical insulation between neighboring pairs of memory cells is achieved by the isolation gate line. The first and the second drain regions are arranged beneath the bit line connections 25 and the node connections 30, respectively.
As shown in
On top of the active area line 15, the substrate's surface 55 is covered with a silicon nitride layer 60 whereas the isolation trenches 20 and other areas of the substrate 50 are covered with silicon oxide 65.
On the pages showing
The figures on each upper left hand side (indicated by suffix “A”) refer to a peripheral part 70 of the memory device 1, which comprises a driving circuit with at least one transistor. The figures on each lower left hand side designated by suffix “D” show a cross section of the peripheral part 70 of the memory device 1 as defined by a line in the corresponding “A”-figure.
The figures in the middle of each page (indicated by suffixes “B” and “E”) refer both to an edge part 75 of the memory device 1 comprising pads for connecting the buried word lines and the bit lines, which pass the array part 2 of the memory device 1. Accordingly, the figures designated by suffixes “B” and “E” show a plan view of the edge part 75 and a cross-section thereof, respectively.
The figures on the right hand side of each page (indicated by suffixes “C” and “F”) refer to the array part 2 comprising the active memory cells of the memory device 1. Accordingly, the figures designated by suffixes “C” and “F” show a plan view of the array part and a cross-section thereof, respectively.
In
It can also be seen that the first conductive layer 80 is covered with an oxide 95 whereas the substrate's surface 55 in the array part 2 and the peripheral part 70 is covered with a nitride layer 105.
In
In
In order to isolate the substrate's surface 55 in the peripheral part 70 from the second conductive layer 110, the oxide layer 106 has been deposited thereon before fabricating the second conductive layer 110. As will be seen below, the oxide layer 106 will form a gate oxide layer for the transistors in the peripheral part 70.
Thereafter, a resist or hard mask 135 is formed on the second conductive layer 110. The resulting structure is etched and the buried word line contact pad 85 is exposed in the edge part 75 (
Then, the mask 135 is removed and a protection layer 140 consisting of silicon nitride is deposited. This protection layer 140 forms a first protection layer 145 in the edge part 75 including a first protective cap 150 that protects the buried word line contact pad 85.
The protection layer 140 simultaneously forms a second protection layer 155 that protects the future bit line 5 in the array part 2. The area of the second protection layer 155 that is situated on top of a future bit line contact pad 160 of the bit line 5 will be referred to as second protective cap 165 hereinafter.
After forming the first and second protective caps 150 and 165, the protection layer 140 is covered with a silicon oxide layer 170 and a resist mask layer 171. The resist mask layer 171 is structured as shown in
By etching the resulting structure, the gate contact layer 130 in the peripheral part 70 is structured forming a structured gate contact layer 175 and gate contact pads 180 for the transistors of the driving circuit (
Thereafter, an oxide layer 185 is deposited and subjected to an anisotropic etch step which removes the horizontal part of the oxide layer 185 in the array part 2 outside the bit line 5 (
In
The previous stud areas 195 are then filled with a third conductive layer 230 of metal such as Tungsten or CoSi and the structure is polished in a CMP step (
In
Then, an intermediate layer 255 (e.g., an oxide layer) is deposited on top of the third protection layer 240 and is structured such that the first protective cap 150, the second protective cap 165, the additional protective cap 181 and the third protective caps 245 and 250 are exposed during the same etch step. During this etch step, an etchant is used that selectively etches the intermediate layer 255 and the oxide 205 faster than the protection layers 240 and 140 (
After exposing the protective caps 150, 165, 181, 245 and 250, they are etched and the underlying contact pads 85, 160, 180 and 235 are exposed (
Thereafter, an oxide layer (e.g., SOG(spin-on-glass)-oxide) 205 is deposited and subjected to a CMP-step. The resulting structure is shown in
In
Afterwards, a third conductive layer 305 is fabricated, which is located directly above and in contact with the exposed gate contact pad 180 (
In order to separate the gate contact pads 180 from the source and drain contact pads 310 and 315, the third conductive layer 305 is subjected to an etch step using a nitride layer 320 and a resist or hard mask 325 (
Then, the third protection layer 330 and the underlying third conductive layer 305 are etched such that the gate contact pad 180, the source contact pad 310 and the drain contact pad 315 are electrically separated from another (
On this structure an intermediate layer 255 is deposited and the structure further processed as explained above with regard to the first embodiment of the invention (see