Methods for preventing cross-linking between multiple resists and patterning multiple resists

Abstract

The present invention prevents cross-linking between multiple resists that are used in the fabrication of a semiconductor device. In order to prevent resists in close proximity or contact with one another from cross-linking, a non-reactive separation layer is disposed between the resists. The separation layer prevents incompatible components of the resists from reacting with one another. Forming the separation layer between the resists allows a resist located above the separation layer to be polymerized and patterned as desired without patterning another resist located below the separation layer. Methods of patterning multiple resists are also disclosed.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to the fabrication of semiconductor devices and, more specifically, to a method of preventing cross-linking between multiple photoresists used in fabrication of the semiconductor device and simultaneously present on a semiconductor device structure under fabrication.

[0003] 2. State of the Art

[0004] Photoresist (“resist”) layers are commonly used during semiconductor device fabrication to pattern a semiconductor substrate. A typical resist comprises a matrix or resin, a sensitizer such as a photoactive compound, and a solvent. When exposed to a specific wavelength of light, the photoactive compound initiates a photochemical reaction that causes the resist to cross-link. Images are patterned onto the semiconductor substrate by exposing portions of the cross-linked resist to the specific wavelength of light. The non-exposed and exposed portions are then developed to produce the desired pattern. Resists are also used to protect features during fabrication of the semiconductor device by covering those features with a resist layer.

[0005] Multiple resists may be used in the fabrication of a semiconductor device, with each resist formed on a portion of the semiconductor device. The resists may be simultaneously present on the intermediate semiconductor device structure. For example, a first resist may be used to protect features on the semiconductor device while a second resist may be formed over an active region of the semiconductor substrate to pattern the substrate. These resists may be formed in close proximity or contact with one another depending on the fabrication process being used. However, if the resists are in close proximity or contact, incompatible components of the resists may react with one another and cause the resists to react or cross-link. Cross-linking between resists is common between deep ultra-violet (“DUV”), I-line, and negative resists that are in close proximity or contact with one another. Cross-linking is especially common between I-line resists and negative resists. While cross-linking is common when at least one of the resists is unpolymerized, it may also occur when both of the resists are polymerized.

[0006] If resists in close proximity or contact cross-link with one another, they become unpatternable by conventional photolithographic processes because the resists are no longer selectively patternable. Therefore, in order to use two resists in close proximity or contact with one another, it would be desirable to be able to eliminate the potential for cross-linking between the resists.

BRIEF SUMMARY OF THE INVENTION

[0007] The present invention relates to the fabrication of semiconductor devices and to a method of preventing cross-linking between resists in an intermediate structure of the semiconductor device. The method includes providing a first resist, forming a separation layer in contact with the first resist, and providing a second resist in contact with the separation layer. The separation layer comprises an organic material that is substantially non-reactive with the first and second resists. The method further comprises patterning or removing the second resist without substantially patterning or removing the first resist. The separation layer and the second resist are simultaneously removed to expose the first resist, which is subsequently removed to expose underlying features of the semiconductor device.

[0008] The present invention also encompasses a method of multi-layer resist patterning. The method comprises providing a first resist in openings located in an active region of an intermediate semiconductor device structure. An organic separation layer is formed in contact with the first resist. A second resist is then provided in contact with the organic separation layer. The second resist is subsequently polymerized and patterned without patterning or removing the first resist. The organic separation layer and the second resist are simultaneously removed to expose the first resist, which is subsequently removed to expose underlying features of the semiconductor device.

[0009] An intermediate semiconductor device structure is also disclosed. The intermediate semiconductor device structure comprises a first resist, a separation layer, and a second resist. The separation layer comprises an organic material that is substantially non-reactive with the first resist and the second resist and that is of sufficient thickness to prevent incompatible components of the first and second resists from reacting with one another.

[0010] The present invention also discloses a container formed during fabrication of a semiconductor device. The container comprises an active region that includes multiple openings filled with a first resist. An organic separation layer is formed in contact with the first resist and a second resist is in contact with the organic separation layer. The organic separation layer is of sufficient thickness to prevent components of the first and second resists from reacting.

DESCRIPTION OF THE DRAWINGS

[0011] By way of example only, an embodiment of the invention will be described with reference to the accompanying drawing:

[0012] FIGS. 1 a and 1b illustrate a container structure in an intermediate semiconductor device structure according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0013] The present invention relates to the fabrication of semiconductor devices and, more specifically, to a method of preventing cross-linking between resists used in the fabrication of semiconductor devices.

[0014] In order to prevent resists from cross-linking, a separation layer may be disposed between the resists to prevent the components of each resist from reacting with one another. The separation layer may be disposed between a first and a second resist so that the first resist is located below the separation layer and the second resist is located above the separation layer. With the separation layer disposed between the two resists, the second resist may be polymerized and patterned, or otherwise processed, without substantially affecting the first resist or features located below the first resist. The separation layer and second resist may subsequently be removed to expose the first resist. It is also contemplated that the separation layer may be used when more than two resists are used in the fabrication process. For example, if three resists are needed in the fabrication process, two separation layers may be necessary. One separation layer may be disposed between the first and second resists and the second separation layer may be disposed between the second and third resists.

[0015] The separation layer of the present invention may be used to prevent cross-linking when the resists are in close proximity or contact with one another during the fabrication of a semiconductor device on a substrate of semiconductor material. As shown in FIGS. 1a and 2, the separation layer may be disposed as a layer that is substantially in contact with both the first and second resists. The separation layer is shown in FIGS. 1a and 2 as bottom anti-reflective (“barc”) layer 11. However, the separation layer may also be selectively disposed between the resists and may be substantially in contact with only one of the resists. As shown in FIG. 1b, the separation layer, shown as barc layer 11, is only substantially in contact with the first resist 12.

[0016] In a multi-layer resist patterning process, the first resist 12 may be used to protect features on the semiconductor device structure, while the second resist 14 may be used to pattern images onto the semiconductor device structure. This first resist 12 may be unpolymerized, making it easy to remove when features protected by that resist need to be exposed or from spaces in which it is typically hard to remove resist. However, it is also contemplated that the separation layer may be disposed between multiple polymerized resists.

[0017] The separation layer comprises a material that is substantially non-reactive with the resists used in the fabrication process. Preferably, the separation layer is an organic material that is easy to apply at a low temperature, such as at approximately 20-23.5° C. The material of the organic separation layer may comprise a conventional spin-on film, a low temperature film, or a spin-on glass. Preferably, the material is applied at approximately 21.5° C. Such an organic separation layer is also preferably easy to remove. The material of the organic separation layer may include, but is not limited to, an organic bare material, an organic anti-reflective (“arc”) material, a polysulfone, or a polyimide. These materials are well known in the art.

[0018] In addition, the separation layer may comprise an inorganic material including, but not limited to, silicon nitride, silicon oxynitride, or silicon oxime. While inorganic materials may be used, organic materials are typically easier to remove and etch than inorganic materials and, therefore, are more desirable. In addition, the organic material is preferred because the organic separation layer and the second resist 14 may be simultaneously removed with one etching process, thereby reducing the number of steps in the fabrication process.

[0019] The required thickness of the separation layer is determined by the chemical properties of the resists used in the particular fabrication process. The separation layer may be of sufficient thickness to prevent the components of each resist from outgassing through the separation layer, thereby preventing incompatible components from coming into contact or close proximity with each other. While the thickness of the separation layer depends on the resists used, the separation layer may be approximately 400-1000 Å thick. Preferably, the separation layer has a thickness of approximately 600 Å.

[0020] In FIG. 1a, a first resist 12 and second resist 14 of container 10 are prevented from cross-linking by a separation layer. The container 10 is formed during fabrication of the semiconductor device and comprises an active region of the semiconductor device, such as oxide layer 16, having multiple openings or trenches. The openings are formed in a manner known in the art and are shown in FIG. 1a as filled with first resist 12. The walls of each opening are lined by a thin layer of polysilicon 13, which is used to create capacitor structures in the semiconductor device. The portions of the oxide layer 16 and polysilicon 13 are planarized and then the openings are filled with first resist 12. The separation layer is deposited over the filled openings and the oxide layer 16. In this embodiment, the separation layer comprises an organic barc layer 11. However, it is to be understood that the separation layer may comprise any organic material previously discussed. The second resist 14 is then deposited over the organic barc layer 11, above portions of the oxide layer 16 that do not comprise openings.

[0021] If the organic barc layer 11 were not present during the fabrication of this container 10, portions of the first resist 12 and adjacent portions of the second resist 14 would cross-link, making the second resist 14 unpatternable. However, with the barc layer 11 present, the first resist 12 and second resist 14 are separated and do not cross-link. The container 10 is subsequently formed by polymerizing the second resist 14 so that it may be patterned as desired. After patterning, the second resist 14 and the barc layer 11 are removed by etching processes known in the art. The second resist 14 and the barc layer 11 may also be simultaneously removed with a wet etch or dry etch process known in the art. The first resist 12 is then removed from the openings to expose the underlying polysilicon 13 for subsequent steps in the fabrication of the semiconductor device.

[0022] Since first resist 12 is not polymerized, it is easy to remove from the openings. However, the method of the present invention may also be used in container 10 if the first resist 12 is polymerized after being deposited in the openings because the barc layer 11 may still be needed to separate the first and second resists.

[0023] While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope thereof as defined by the following appended claims.

Claims

1. A method of preventing cross-linking between resists on an intermediate semiconductor device structure comprising: providing a first resist; forming a separation layer substantially in contact with said first resist; and providing a second resist substantially in contact with said separation layer, wherein said separation layer is substantially non-reactive with said first resist and said second resist.

2. The method of claim 1, wherein forming a separation layer substantially in contact with said first resist comprises disposing an organic material substantially in contact with said first resist.

3. The method of claim 2, wherein forming a separation layer substantially in contact with said first resist comprises disposing one of an anti-reflective material, a bottom antireflective material, a polysulfone, and a polyimide substantially in contact with said first resist.

4. The method of claim 1, wherein forming a separation layer substantially in contact with said first resist comprises disposing an organic, bottom anti-reflective material substantially in contact with said first resist.

5. The method of claim 1, wherein forming a separation layer substantially in contact with said first resist comprises forming said separation layer at a low temperature.

6. The method of claim 1, wherein forming a separation layer substantially in contact with said first resist comprises disposing an inorganic material substantially in contact with said first resist.

7. The method of claim 1, wherein providing a first resist comprises providing one of a deep ultra-violet resist, a negative resist, and an I-line resist.

8. The method of claim 1, wherein providing a second resist comprises providing one of a deep ultra-violet resist, a negative resist, and an I-line resist.

9. The method of claim 1, wherein providing a first resist comprises providing an unpolymerized resist and wherein providing a second resist comprises providing a polymerized resist.

10. The method of claim 9, further comprising: simultaneously removing said second resist and said separation layer to expose said first resist.

11. The method of claim 10, further comprising: removing said first resist to expose features underlying said first resist.

12. The method of claim 1, wherein providing a first resist comprises providing a polymerized resist and wherein providing a second resist comprises providing a polymerized resist.

13. The method of claim 1, wherein forming a separation layer substantially in contact with said first resist comprises forming a separation layer in contact with said first resist and wherein forming a separation layer substantially in contact with said second resist comprises forming a separation layer in contact with said second resist.

14. The method of claim 1, wherein forming a separation layer substantially in contact with said first resist and said second resist comprises one of forming a separation layer substantially in contact with said first resist and forming a separation layer substantially in contact with said second resist.

15. The method of claim 1, further comprising: polymerizing said second resist; and patterning said second resist without substantially patterning or removing said first resist.

16. The method of claim 1, wherein forming a separation layer substantially in contact with said first resist comprises forming a separation layer of a sufficient thickness to prevent components of said first resist and said second resist from reacting.

17. The method of claim 16, wherein forming a separation layer of a sufficient thickness to prevent components of said first resist and said second resist from reacting comprises forming a separation layer of a sufficient thickness to prevent components of said first resist and said second resist from cross-linking.

18. A method of preventing cross-linking between resists in an intermediate semiconductor device structure comprising: providing a first resist; forming an organic separation layer substantially in contact with said first resist; and providing a second resist substantially in contact with said organic separation layer, wherein said organic separation layer is substantially non-reactive with said first resist and said second resist.

19. The method of claim 18, wherein forming an organic separation layer substantially in contact with said first resist comprises forming said organic separation layer at a low temperature.

20. The method of claim 18, wherein forming an organic separation layer substantially in contact with said first resist comprises disposing one of an organic anti-reflective material, an organic bottom anti-reflective material, a polysulfone, and a polyimide substantially in contact with said first resist.

21. The method of claim 18, wherein forming an organic separation layer substantially in contact with said first resist comprises disposing an organic, bottom anti-reflective material substantially in contact with said first resist.

22. The method of claim 18, wherein providing a first resist comprises providing one of a deep ultra-violet resist, a negative resist, and an I-line resist.

23. The method of claim 18, wherein providing a second resist comprises providing one of a deep ultra-violet resist, a negative resist, and an I-line resist.

24. The method of claim 18, wherein providing a first resist comprises providing an unpolymerized resist and wherein providing a second resist comprises providing a polymerized resist.

25. The method of claim 24, further comprising: simultaneously removing said second resist and said organic separation layer to expose said first resist.

26. The method of claim 25, further comprising: removing said first resist to expose features underlying said first resist.

27. The method of claim 18, wherein providing a first resist comprises providing a polymerized resist and wherein providing a second resist comprises providing a polymerized resist.

28. The method of claim 18, wherein forming an organic separation layer substantially in contact with said first resist comprises forming an organic separation layer in contact with said first resist and wherein forming an organic separation layer substantially in contact with said second resist comprises forming an organic separation layer in contact with said second resist.

29. The method of claim 18, wherein forming an organic separation layer substantially in contact with said first resist and said second resist comprises one of forming an organic separation layer in contact with said first resist and forming an organic separation layer in contact with said second resist.

30. The method of claim 18, further comprising: polymerizing said second resist; and patterning said second resist without substantially patterning or removing said first resist.

31. The method of claim 18, wherein forming an organic separation layer substantially in contact with said first resist comprises forming an organic separation layer of a sufficient thickness to prevent components of said first resist and said second resist from reacting.

32. The method of claim 31, wherein forming an organic separation layer of a sufficient thickness to prevent components of said first resist and said second resist from reacting comprises forming a separation layer of a sufficient thickness to prevent components of said first resist and said second resist from cross-linking.

33. A method of multi-layer resist patterning on an intermediate semiconductor device structure comprising: providing a first resist in openings located in an active region of said intermediate semiconductor device structure; forming an organic separation layer substantially in contact with said first resist; and providing a second resist substantially in contact with said organic separation layer.

34. The method of claim 33, wherein forming an organic separation layer substantially in contact with said first resist comprises forming said organic separation layer at a low temperature.

35. The method of claim 33, wherein forming an organic separation layer substantially in contact with said first resist comprises disposing one of an organic anti-reflective material, an organic bottom anti-reflective material, a polysulfone, and a polyimide substantially in contact with said first resist.

36. The method of claim 33, wherein forming an organic separation layer substantially in contact with said first resist comprises disposing an organic bottom anti-reflective material substantially in contact with said first resist.

37. The method of claim 33, wherein providing a first resist in openings located in an active region of said intermediate semiconductor device structure comprises providing one of a deep ultra-violet resist, a negative resist, and an I-line resist in said openings.

38. The method of claim 33, wherein providing a second resist comprises providing one of a deep ultra-violet resist, a negative resist, and an I-line resist.

39. The method of claim 33, wherein providing a first resist in openings located in an active region of said intermediate semiconductor device structure comprises providing an unpolymerized resist and wherein providing a second resist comprises providing a polymerized resist.

40. The method of claim 39, further comprising: simultaneously removing said second resist and said organic separation layer to expose said first resist.

41. The method of claim 40, further comprising: removing said first resist to expose underlying features.

42. The method of claim 33, wherein forming an organic separation layer substantially in contact with said first resist comprises forming an organic separation layer in contact with said first resist and wherein forming an organic separation layer substantially in contact with said second resist comprises forming an organic separation layer in contact with said second resist.

43. The method of claim 33, wherein forming an organic separation layer substantially in contact with said first resist and said second resist comprises one of forming an organic separation layer in contact with said first resist and forming an organic separation layer in contact with said second resist.

44. The method of claim 33, further comprising: polymerizing said second resist; and patterning said second resist without substantially patterning or removing said first resist.

45. The method of claim 33, wherein forming an organic separation layer substantially in contact with said first resist comprises forming an organic separation layer of a sufficient thickness to prevent components of said first resist and said second resist from reacting.

46. A method of multi-layer resist patterning on an intermediate semiconductor device structure comprising: providing two resists separated by an organic separation layer, wherein a first resist is located below said organic separation layer and a second resist is located above said organic separation layer; polymerizing said second resist; patterning said second resist without substantially patterning or removing said first resist; removing said second resist and said organic separation layer; and removing said first resist.

47. The method of claim 46, wherein providing two resists separated by an organic separation layer comprises providing two resists separated by an organic anti-reflective material, an organic bottom anti-reflective material, a polysulfone, or a polyimide.

48. The method of claim 46, wherein providing two resists separated by an organic separation layer comprises providing two resists separated by an organic bottom antireflective material.

49. The method of claim 46, wherein providing two resists separated by an organic separation layer comprises providing two resists separated by an organic separation layer formed at a low temperature.

50. The method of claim 46, wherein providing two resists separated by an organic separation layer comprises providing two resists each comprised of one of a deep ultra-violet resist, a negative resist, and an I-line resist.

51. The method of claim 46, wherein providing two resists separated by an organic separation layer comprises providing two resists substantially in contact with said organic separation layer.

52. The method of claim 46, wherein providing two resists separated by an organic separation layer comprises providing one of the two resists substantially in contact with said organic separation layer.

53. The method of claim 46, wherein providing two resists separated by an organic separation layer comprises providing two resists separated by an organic separation layer of a sufficient thickness to prevent components of said two resists from reacting.

54. The method of claim 46, wherein removing said second resist and said organic separation layer comprises simultaneously removing said second resist and said organic separation layer.

55. An intermediate semiconductor device structure comprising: a substrate; a first resist on said substrate; a separation layer substantially in contact with said first resist; and a second resist on said substrate substantially in contact with said separation layer, wherein said separation layer is substantially non-reactive with said first resist and said second resist.

56. The intermediate semiconductor device structure of claim 55, wherein said separation layer comprises an organic material.

57. The intermediate semiconductor device structure of claim 55, wherein said organic material is one of an organic anti-reflective material, an organic bottom anti-reflective material, a polysulfone, and a polyimide.

58. The intermediate semiconductor device structure of claim 55, wherein said organic material comprises an organic bottom anti-reflective material.

59. The intermediate semiconductor device structure of claim 55, wherein said separation layer comprises an inorganic material.

60. The intermediate semiconductor device structure of claim 55, wherein said separation layer is of a sufficient thickness to prevent components of said first resist and said second resist from reacting.

61. The intermediate semiconductor device structure of claim 55, wherein each of said first resist and said second resist comprises one of a deep ultra-violet resist, a negative resist, and an I-line resist.

62. The intermediate semiconductor device structure of claim 55, wherein said first resist is an unpolymerized resist and said second resist is a polymerized resist.

63. The intermediate semiconductor device structure of claim 55, wherein one of said first resist or said second resist is in contact with said separation layer.

64. The intermediate semiconductor device structure of claim 55, wherein said first resist and said second resist are in contact with said separation layer.

65. A container structure formed during the fabrication of a semiconductor device comprising: an active region comprising multiple openings in a portion of said active region; a first resist filling said multiple openings; an organic separation layer in contact with said first resist; and a second resist in contact with said organic separation layer, wherein said organic separation layer is substantially non-reactive with said first resist and said second resist.

66. The container structure of claim 65, wherein said organic separation layer is one of an organic anti-reflective material, an organic bottom anti-reflective material, a polysulfone, and a polyimide.

67. The container structure of claim 65, wherein said organic separation layer comprises an organic bottom anti-reflective material.

68. The container structure of claim 65, wherein each of said first resist and said second resist comprises one of a deep ultra-violet resist, a negative resist, and an I-line resist.

69. The container structure of claim 65, wherein said organic separation layer is of a sufficient thickness to prevent components of said first resist and said second resist from reacting.

70. The container structure of claim 65, wherein said first resist is an unpolymerized resist and said second resist is a polymerized resist.

71. The container structure of claim 65, wherein said first resist and said second resist are substantially in contact with said organic separation layer.

72. The container structure of claim 65, wherein said first resist overlies a thin polysilicon film.

73. The container structure of claim 65, wherein said second resist overlies a portion of said active region that does not comprise said multiple openings.

74. An intermediate semiconductor device structure comprising: a first resist; an organic separation layer substantially in contact with said first resist; and a second resist substantially in contact with said organic separation layer, wherein said organic separation layer is substantially non-reactive with said first resist and said second resist.

75. The intermediate semiconductor device structure of claim 74, wherein said organic separation layer is one of an organic anti-reflective material, an organic bottom anti-reflective material, a polysulfone, and a polyimide.

76. The intermediate semiconductor device structure of claim 74, wherein said organic separation layer comprises an organic bottom anti-reflective material.

77. The intermediate semiconductor device structure of claim 74, wherein each of said first resist and said second resist comprises one of a deep ultra-violet resist, a negative resist, and an I-line resist.

78. The intermediate semiconductor device structure of claim 74, wherein said organic separation layer is of a sufficient thickness to prevent components of said first resist and said second resist from reacting.

79. The intermediate semiconductor device structure of claim 74, wherein said first resist is an unpolymerized resist and said second resist is a polymerized resist.

80. The intermediate semiconductor device structure of claim 74, wherein one of said first resist and said second resist is in contact with said organic separation layer.

81. The intermediate semiconductor device structure of claim 74, wherein said first resist and said second resist are in contact with said organic separation layer.