The present disclosure is related to devices having via interconnects, and particularly to integrated circuit devices having offset via connections.
During the manufacture of integrated circuit devices, individual semiconductor components fabricated at a substrate are connected together using conductive lines and vias to implement a desired function. The process of forming connections between components is generally referred to as metallization and can include connections at multiple interconnect levels. One type of interconnect level, generally referred to as a metal level, contains a plurality of conductive lines separated from each other by dielectric material. Conductive lines at different levels can be electrically connected to each other through conductive structures referred to as vias that are formed within a dielectric material residing between metal levels.
An ideal contact between a via and a conductive line provides a low-resistance interface with low susceptibility to electromigration. While an interface at the time of manufacture may provide an adequate contact between a via and the conductive line that it contacts, stresses at the via/conductive line interface can result in peeling at the interface, which can facilitate undesirable electromigration over time. It has been observed that near-borderless vias demonstrate significantly higher stresses at their interface with conductive lines than do borderless vias, thereby resulting in additional reliability concerns. Therefore, a method and apparatus that improves the reliability of the electrical connection at the via/conductive line interface for near-borderless vias, and other vias, would be useful.
The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
The use of the same reference symbols in different drawings indicates similar or identical items.
In accordance with a specific embodiment of the present disclosure, a via is formed in contact with a conductive line, whereby the via is offset from the conductive line so that the via extends beyond an upper surface of the conductive line. In accordance with a specific embodiment, a portion of the via contacts a sidewall of the conductive line. The use of an offset via reduces stress at the interface between the via and conductive line, as compared to a borderless via, and facilitates positive shunting of current between the via and the conductive line.
Specific embodiments of the present disclosure will be better understood with reference to
A via typically has a width that is the same as, or smaller than a conductive line to which it contacts. The term “borderless via” is intended to mean a via having an outer vertical edge (sidewall) that is aligned to a sidewall of a conductive line to which it contacts such that the outer vertical edge of the via and the sidewall of the conductive line are in a common plane defined by the sidewall of the conductive line as illustrated by via 111 illustrated at
The term “near-borderless via” is intended to mean a via having one or more outer vertical edges that are formed slightly within the outer edges of the conductive line as illustrated by via 112 at
The term “bordered via” is intended to mean a via that contacts the conductive line such that the edges of the via are well within the outer edges of the conductive line as illustrated by via 113 at
A via having a width about the same as the width of its conductive line is often used when the conductive line carries a signal between components (a signal line). A via having a width significantly less than its conductive line is often used when the conductive line provides a voltage reference, such as Vdd or GND, to many components.
The term “substrate” as used herein is intended to mean a base material that can be either rigid or flexible and may include one or more layers of one or more materials, which can include, but is not limited to, one or more of semiconductor, dielectric, polymer, metal, ceramic materials, or combinations thereof. The reference point for a substrate is the beginning point of a process sequence. For example,
The term “substrate surface” is intended to refer to a major surface of the initial base material of the substrate. For example, substrate 210 of
The term “surface,” with respect to a structure formed at a substrate, is intended to refer to one of two surfaces substantially parallel to the substrate surfaces. The term “top surface,” with respect to a surface of a structure formed at a substrate, is intended to refer to a surface of the structure that is substantially parallel to a substrate surface and furthest from the substrate. The term “bottom surface,” with respect to a surface of a structure formed at a substrate, is intended to refer to the surface of the structure that is substantially parallel to a substrate surface and closest to the substrate. With respect to the conductive line 411 illustrated at
The term “side wall,” with respect to a structure formed at a substrate, is intended to refer to a surface substantially perpendicular the structure's top and bottom surface. With respect to
The terms “height,” “length,” and “width,” when referring to a structure overlying a substrate, are intended to refer to dimensions substantially perpendicular to each other. “Height” is intended to refer to a dimension substantially perpendicular to the substrate surface at which it is formed. For example, with reference to
At block 192 of
At block 193 of
In accordance with a specific embodiment, an opening is formed in a material at level 312 to define conductive line 332. In one embodiment, conductive line 332 is formed at level 312 and includes a barrier layer 318 (outer layer) and core layer 331, whereby the core layer 331 is isolated from dielectric layer 319 by barrier layer 318. After formation of conductive line 332, a dielectric is formed at level 313 overlying conductive line 332. The dielectric at level 313 is illustrated to include an etch stop layer 346 and a dielectric layer 349 that can be etched selectively relative the etch stop layer 346. A via opening that is offset relative to the conductive line is formed using a stencil mask to pattern a resist layer. In the specific embodiment, the via opening is formed through level 313 and into level 312 to expose a sidewall portion of the conductive line 332. Note that in the illustrated embodiment an over etch is performed after detection of etch stop layer 346. A via 341 that electrically contacts the conductive line 332 is formed through level 313 and into level 312. Note that only a portion of the bottom surface of via 341 is in contact with the top surface of conductive line 332. In a specific embodiment, via 341 includes a barrier layer 348 and a conductive core 347, such as copper, aluminum, and the like.
In accordance with a specific embodiment, the offset distance 382 of via 341 is between 10% and 40% of the total width 381 of the via 341 as measured along a dimension perpendicular to the side surface of the conductive line. Note with respect to
Selection of a via offset sufficiently large to accommodate formation of a flat via bottom within layer 312 is more desirable than a via offset that results in a rounded narrower bottom within layer 312 that is more rounded.
Conductive line 332 includes a conductive core layer 331 and a conductive barrier layer 318. The barrier layer 318 is made from a material different than the core layer 331 and the dielectric layer 319. The barrier layer prevents contamination between conductive core 331 and adjacent dielectric 319 materials. Similarly, via 341 includes a conductive core layer 347 and a conductive barrier layer 348. The barrier layer 348 is made from a material different from the core layer 347. A sidewall of the via 341 is defined by the interface of the barrier layer 348 and the dielectric 349. Conductive cores 331 and 347 can include one or more conductive materials including a metal-containing component, a metal, or a metal alloy. Suitable metals can include transition metals, such as copper, aluminum, or the like. In an alternate embodiment, the conductive line of
The via 341 includes a conductive core layer 347 and a conductive barrier layer 348. The conductive core 347 and barrier layer 348 are formed from different materials and perform similar functions as previously described with respect to conductive line 332. In an alternate embodiment, the barrier layer 348 can include a thin adhesion layer formed on the conductive line 332 and on the exposed dielectric materials at levels 312 and 313 to facilitate adhesion of subsequently deposited material. According to a particular embodiment, adhesion metals can include nitrogen-containing components, such as those including transition metals, and particularly tantalum nitride (TaN), titanium nitride (TiN), tungsten nitride (WN) and the like. These nitrogen-containing compounds have good adhesion to the dielectric materials and provide good barrier resistance to the diffusion of copper from the copper conductor materials to the surrounding dielectric material. High barrier resistance with conductor materials, such as copper, helps to prevent diffusion of subsequently deposited conductive material into the dielectric layer, which can cause short circuits in the integrated circuit. However, some of these nitride barrier materials have relatively poor adhesion to copper and relatively high electrical resistance. Because of these drawbacks, pure refractory metals such as tantalum (Ta), titanium (Ti), tungsten (W), and the like can be formed at an adhesion layer of barrier layer 348. The refractory metals are good barrier materials, generally having lower electrical resistance than nitride barrier materials, and having good adhesion to copper. It will be appreciated, that in some cases, the barrier material has sufficient adhesion to the dielectric material that the adhesion layer is not required, and in other cases, the adhesion and barrier material become integral. The term “barrier layer,” as used in reference with vias and conductive lines, is intended to refer collectively to the adhesion and barrier materials describe above.
The formation and use of intentionally offset vias that extend past a sidewall edge of the conductive line to which they contact improves electromigration characteristics of semiconductor devices using borderless and near-borderless vias. For example, these improvements increase the amount of interface linkage at the metal etch stop/conductive line interface, thereby reducing peeling stress between the etch stop layer and the via. In addition, the formation and use of vias extending beyond the edge of the conductive line also promotes a positive shunting effect. The minimum pitch between vias can be maintained by applying the offset to all vias at a common level to avoid adversely affecting dielectric breakdown.
At 602, a first feature of the first stencil mask is defined. The first feature defining a via location for a semiconductor device interconnect. The first feature at the first stencil mask intentionally offset from a second feature of the second stencil mask that defines a conductive line. The intentional offset being an amount greater than maximum amount of random alignment variation to assure the first feature is offset from an edge of the second feature.
Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which they are performed. After reading this specification, skilled artisans will be capable of determining what activities can be used for their specific needs or desires.
In the foregoing specification, principles of the invention have been described above in connection with specific embodiments. However, one of ordinary skill in the art appreciates that one or more modifications or one or more other changes can be made to any one or more of the embodiments without departing from the scope of the invention as set forth in the claims below. For example, it will be appreciated that in various embodiments, the barrier layers are of materials such as tantalum (Ta), titanium (Ti), tungsten (W), compounds thereof, and combinations thereof. The seed layers (where used) are of materials such as copper (Cu), gold (Au), silver (Ag), compounds thereof and combinations thereof with one or more of the above elements. The conductor cores with or without seed layers are of materials such as copper, aluminum (Al), gold, silver, compounds thereof, and combinations thereof. The dielectric layers are of dielectric materials such as silicon oxide (SiO), tetraethoxysilane (TEOS), borophosphosilicate (BPSG) glass, etc. with dielectric constants from 4.2 to 3.9 or low dielectric constant dielectric materials such as fluorinated tetraethoxysilane (FTEOS), hydrogen silsesquioxane (HSQ), benzocyclobutene (BCB), etc. with dielectric constants below 3.9. The stop layers and capping layers (where used) are of materials such as silicon nitride (Six Nx) or silicon oxynitride (SiON).
It will be further appreciated that the vias can be formed as part of a dual inlaid process, or formed separately from overlying conductive lines. When the via is formed separate from the overlying conductive line, the via can be offset from both conductive lines. For example,
Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense and any and all such modifications and other changes are intended to be included within the scope of invention.
Any one or more benefits, one or more other advantages, one or more solutions to one or more problems, or any combination thereof have been described above with regard to one or more specific embodiments. However, the benefit(s), advantage(s), solution(s) to problem(s), or any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced is not to be construed as a critical, required, or essential feature or element of any or all the claims.