This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2013-062590, filed Mar. 25, 2013, the entire contents of which are incorporated herein by reference.
Embodiments described herein relate generally to a semiconductor device and a method of manufacturing the same.
As semiconductor devices are refined more highly, their metal interconnect decreases in its width and height. This causes a problem that the interconnect width and height get closer to the mean free path of conduction electrons and an interface inelastic scattering effect increases electrical resistivity. In particular, if the interconnect width and height are almost equal to or not greater than the mean free path, the interface inelastic scattering effect increases electrical resistivity more greatly. To prevent the electrical resistivity from increasing, it is proposed to use graphene interconnect that is less influenced by the interface inelastic scattering effect.
However, when the interconnect length is shorter than the ballistic conduction length, the resistance of the graphene interconnect is higher than that of the metal interconnect. It is thus inexpedient to use graphene interconnect for all the interconnect.
Therefore, a structure and a method capable of forming low-resistance interconnect even though the interconnect width and height are decreased, is desired.
It is considered that graphene is formed by supplying carbon to the facet of an underlying layer. Since, however, the location or shape of the facet is not sufficiently controlled, there is a problem that a good-quality, uniform graphene layer is not formed.
Therefore, a structure and a method capable of forming a good-quality, uniform graphene layer have been desired.
In general, according to one embodiment, a semiconductor device comprises: a metal interconnect and a graphene interconnect which are stacked to one another.
Embodiments will be described below with reference to the accompanying drawings.
Referring first to
Referring next to
Referring next to
Referring next to
Referring next to
Referring next to
Referring next to
Referring next to
Referring next to
Referring next to
Through the above process, a semiconductor device as shown in
As has been described, there is a problem that as the interconnect width and height of the metal interconnect get closer to the mean free path of conduction electrons, an interface inelastic scattering effect increases electrical resistivity. For example, in copper (Cu) used for copper interconnect, the mean free path of conduction electrons is about 40 nm. In graphene, the mean free path of conduction electrons is about 100 nm to 1 μm, which allows low-resistance interconnect using quantization conduction. However, in interconnect whose length is shorter than the ballistic conduction length, the resistance of the graphene interconnect is higher than that of the metal interconnect. In interconnect whose width and height are great, the metal interconnect is more advantageous. It is thus inexpedient to use graphene interconnect for all the interconnect. Furthermore, it is difficult in design terms to use metal interconnect and graphene interconnect properly according to interconnect length, interconnect width and interconnect height.
As described above, in the semiconductor device according to the first embodiment, the interconnect is formed by stacked interconnect including the metal interconnect 17 and graphene interconnect 19. In other words, substantially the entire part of the interconnect is a stacked structure of the metal interconnect 17 and graphene interconnect 19. For this reason, the metal interconnect is used chiefly as a current path on a priority basis in an interconnect portion whose length is less than the ballistic conduction length of graphene interconnect, and the graphene interconnect is used chiefly as a current path on a priority basis in an interconnect portion whose length is greater than the ballistic conduction length of graphene interconnect. In an interconnect portion whose interconnect width and interconnect height are greater, the metal interconnect is used as a current path on a priority basis. In the first embodiment, therefore, low-resistance interconnect can be achieved in substantially all the interconnect portions without making it difficult in design terms to use metal interconnect and graphene interconnect properly.
In the semiconductor device according to the first embodiment, the catalyst layer 18 is selectively formed on the metal interconnect 17 and graphene interconnect 19 is selectively formed on the catalyst layer 18. Accordingly, the graphene interconnect 19 can be aligned with the metal interconnect 17. It is thus possible to form the stacked interconnect of the metal interconnect 17 and graphene interconnect 19 easily and reliably.
In the foregoing embodiment, a plug connected to the graphene interconnect 19 can be formed as follows. For example, after contact metal (Ti, Ta, Hf, etc.) is formed, barrier metal (e.g., TiN) can be formed and then a tungsten (W) plug can be formed through CVD-W process.
In the foregoing embodiment, a selective CVD process can be employed to form the catalyst layer 18 on the metal interconnect 17 selectively.
In the foregoing embodiment, the number of graphene layers to form the graphene interconnect (multilayered graphene interconnect) can be determined as follows. For example, the number of graphene layers to form graphene interconnect can be determined such that the resistance of graphene interconnect having a length similar to the ballistic length of the graphene interconnect and that of metal interconnect having a length similar to the ballistic length of the graphene interconnect become equal to each other. This facilitates resistivity design.
In the foregoing embodiment, the catalyst layer is formed on the Cu damascene interconnect. However, as the interconnect becomes fine, metal materials whose mean free path is short, such as W, Mo and Ru may be used as interconnect materials. The catalyst layer and graphene interconnect can be formed on the interconnect using these metal materials. If the interconnect materials are changed, the processing method may also be changed. For example, in order to form interconnect by RIE, a catalyst layer can be stacked on a metal interconnect material layer and then the catalyst layer and the metal interconnect material layer can be shaped into interconnect at once. Similarly, in order to form interconnect by RIE, a metal interconnect material layer can be shaped into interconnect and then a catalyst layer can be formed to cover the layer shaped into interconnect.
In the second embodiment, after the metal interconnect 17 is formed in the step shown in
In general, graphene is easy to grow from an edge such as a corner of a trench. In the second embodiment, a process of depressing the top surface of the copper interconnect 16 is performed and thus the top surface of the catalyst layer 18 formed on the copper interconnect 16 can be made lower than that of its surrounding insulation film 13. As a result, graphene of good quality can easily be grown from the corner (edge) of a trench which is a starting point.
In the first embodiment, the copper interconnect 16 is formed through the damascene process. Instead of the copper interconnect 16, tungsten (W) interconnect, molybdenum (Mo) interconnect or ruthenium (Ru) interconnect can be formed through the RIE process. In particular, as the interconnect becomes fine, these metal materials whose mean free path is short are very likely to be used to prevent an increase in resistance due to the narrow line effect. More specifically, a W layer (or a Mo layer and a Ru layer) is formed on an insulation film 41 as a metal interconnect material layer 44 and then a catalyst layer (a cap metal layer) 45 is formed on the metal interconnect material layer 44. For control of catalyst orientation, a catalyst orientation control layer (a promoter layer) can be formed on the metal interconnect material layer 44 and then the catalyst layer 45 can be formed. After the metal interconnect material layer and the others are processed to form interconnect 44, a graphene layer (graphene interconnect) 46 is formed. After that, insulation films 42, 43 and 47 are formed and a plug 48 is formed, with the result that a structure as shown in
As described above, instead of the interconnect (damascene interconnect) formed through the damascene process, interconnect (RIE interconnect) can be formed through the RIE process and graphene interconnect 46 can be formed on the RIE interconnect. In this case, too, the same advantage as that of the first embodiment can be brought about.
In the example of
The catalyst layer can be formed on the catalyst orientation control layer or directly formed on the metal interconnect.
In the foregoing first to third embodiments, the top surface of the graphene interconnect is brought into contact with the plug. However, the plug can be formed to penetrate the graphene interconnect or penetrate the graphene interconnect and the catalyst layer. In these cases, the graphene interconnect and the plug are connected to each other on the side of a through hole formed in the graphene interconnect. For example,
In the first embodiment, the graphene interconnect is formed on the metal interconnect. In the fourth embodiment, however, the metal interconnect is formed on the graphene interconnect. More specifically, a barrier metal film 54, a catalyst layer 55, a graphene layer 56 and a metal film 57 are formed in sequence on an insulation film 51. After that, the barrier metal film 54, catalyst layer 55, graphene layer 56 and metal film 57 are patterned by photolithography and RIE to form stacked interconnect including graphene interconnect 56 and metal interconnect 57. Insulation films 52, 53 and 58 are formed and then a plug 59 is formed, with the result that a structure as shown in
If the metal interconnect 57 is formed on the graphene interconnect 56 to form stacked interconnect, low-resistance interconnect can be achieved in substantially all the interconnect portions without making it difficult in design terms to use metal interconnect and graphene interconnect properly, as in the first embodiment.
After the barrier metal film 54 and the catalyst layer 55 are formed in an interconnect pattern form, the graphene interconnect 56 can selectively be formed on the catalyst layer 55 and then the metal interconnect 57 can be formed by RIE.
In the foregoing first to fourth embodiments, the plug connected to the stacked interconnect of the metal interconnect and the graphene interconnect can be made of metal or carbon nanotube (CNT).
First, an insulation film 61 is formed on an underlying region 60 including a semiconductor substrate (not shown) and a semiconductor element (not shown) such as a transistor, and an insulation film 62 is formed on the insulation film 61. The insulation films 61 and 62 serve as an insulation region. As the insulation film 62, a silicon oxide film is used and, more specifically, a TEOS oxide film is used. Then, a hole is formed in the insulation films 61 and 62 and a plug 63 is formed in this hole. The plug 63 is made of metal material such as W, Cu and Al. Barrier metal can be formed on the inner surface of the hole. As the material of the barrier metal, Ta, Ti, Ru, Mn, Co or nitride of these metals can be used.
Next, the insulation film 62 is recessed by RIE and accordingly it has an inclined surface around the exposed portion of the plug 63 (the top of the plug 63). More specifically, the insulation film 62 remains on the side wall of the top portion of the plug 63 and an inclined surface is formed on the remaining insulation film 62. The angle of the inclined surface is set to about 30 to 60 degrees with respect to the horizontal plane. The depth of the recessed insulation film 62 is set to about 1 to 50 nm.
Next, a Ti/TiN film having a thickness of about 1 to 20 nm is formed as a barrier metal film 64 on the recessed insulation film 62 and on the exposed portion of the plug 63 (the top of the plug 63) by PVD. In general, Ti, Ta, Mn, Ru, Ir, Cu, Zn, an alloy containing these metals, or nitride of these metals can be used for the barrier metal film 64. The barrier metal film 64 can be formed by CVD as well as PVD. Further, the barrier metal film 64 serves as a promoter layer for controlling the orientation of a catalyst layer 65 described later.
Next, a Ni film having a thickness of about 1 to 50 nm is formed as the catalyst layer 65 on the barrier metal film 64 by PVD or CVD. A film containing at least one of Co, Ni and Fe as the principal ingredient can be used as the catalyst layer 65. Since the insulation film 62 has an inclined surface, its corresponding inclined surface of the catalyst layer 65 serves as a facet.
Next, a graphene layer 66 is formed on the catalyst layer 65. The graphene layer 66 is formed by CVD, for example. Hydrocarbon-based gas (methane, acetylene, etc.) or mixed gas containing the hydrocarbon-based gas is used as a carbon source of the CVD. Hydrogen gas or noble gas is used as carrier gas. Favorably, the temperature at which the graphene layer 66 is formed falls within a range from 200° C. to 1000° C. More favorably, the temperature falls within a range from 500° C. to 600° C. In order to eliminate ions and electrons using remote plasma, an electrode can be provided above a substrate to be treated in order to apply a voltage. Favorably, the voltage applied to form the graphene layer 66 is 0 to about ±100V.
The graphene layer 66 grows from the facet of the catalyst layer 65 formed to correspond to the inclined surface of the insulation film 62. Thus, a good-quality, uniform graphene layer 66 can be achieved. The catalyst layer 65 and graphene layer 66 are oriented toward (111) face of the face-centered structure or (002) face of the hexagonal close-packed structure. Accordingly, the graphene layer 66 is formed on the insulation film 62 and the exposed portion of the plug 63 with the barrier metal film 64 and catalyst layer 65 interposed between them.
Furthermore, the graphene layer 66 is patterned by photolithography and RIE to form graphene interconnect 66.
As described above, in the fifth embodiment, the insulation film 62 has an inclined surface around the exposed portion of the plug 63. Thus, the good-quality, uniform graphene layer 66 can be grown from the facet of the catalyst layer 65 formed to correspond to the inclined surface. Using the graphene layer 66 so formed, graphene interconnect of good quality can be obtained.
In the fifth embodiment, the horizontal plane of the insulation film 62 is lower than the top surface of the plug 63. In the sixth embodiment, however, the horizontal plane of an insulation film 62 is higher than the top surface of a plug 63 and, in this case, too, the insulation film 62 has an inclined surface around the exposed portion (top surface) of the plug 63. The angle of the inclined surface is set to about 30 to 60 degrees with respect to the horizontal plane. A graphene layer 66 grows from the facet of a catalyst layer 65 formed to correspond to the inclined surface of the insulation film 62.
In the sixth embodiment, too, the insulation film 62 has an inclined surface. Therefore, as in the fifth embodiment, a good-quality, uniform graphene layer 66 can be formed to grow from the facet of the catalyst layer 65, with the result that good-quality graphene interconnect can be obtained.
In the seventh embodiment, a plug 63 is formed as in the fifth embodiment and then a conductive structure 67 having a slanted surface is formed selective on the plug 63 by selective CVD or electroless plating. The conductive structure 67 can be made of metal or metal nitride. More specifically, the conductive structure 67 can be made of TiN, Ru, TaN, RuN, Co, CoN, Ni, NiN, W, Cu, CoW or the like. The thickness (height) of the conductive structure 67 is about 1 to 30 nm. The angle of the inclined surface of the conductive structure 67 is about 30 to 60 degrees with respect to the horizontal plane.
After that, as in the fifth embodiment, a barrier metal film 64, a catalyst layer 65 and a graphene layer 66 are formed. In order to correspond to the inclined surface of the conductive structure 67, the inclined surface of the catalyst layer 65 serves as a facet. The graphene layer 66 grows from the facet of the catalyst layer 65.
In the seventh embodiment, the conductive structure 67 has an inclined surface. Therefore, as in the fifth embodiment, a good-quality, uniform graphene layer 66 can be formed to grow from the facet of the catalyst layer 65, with the result that good-quality graphene interconnect can be obtained.
Furthermore, in the seventh embodiment, the conductive structure 67 is formed and then the barrier metal film 64, catalyst layer 65 and graphene 66 are formed. If, however, the conductive structure 67 is made of barrier metal materials, the barrier metal film 64 need not be formed.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
Number | Date | Country | Kind |
---|---|---|---|
2013-062590 | Mar 2013 | JP | national |
Number | Name | Date | Kind |
---|---|---|---|
5162261 | Fuller | Nov 1992 | A |
6136624 | Kemmochi | Oct 2000 | A |
20090136412 | Awano et al. | May 2009 | A1 |
20110006425 | Wada et al. | Jan 2011 | A1 |
20110101528 | Akimoto | May 2011 | A1 |
20120080661 | Saito et al. | Apr 2012 | A1 |
Number | Date | Country |
---|---|---|
2000-191302 | Jul 2000 | JP |
2009-70911 | Apr 2009 | JP |
2010-62333 | Mar 2010 | JP |
2012-74682 | Apr 2012 | JP |
2012-80006 | Apr 2012 | JP |
Entry |
---|
First Office Action issued by the Japanese Patent Office on Jun. 30, 2015, for Japanese Patent Application No. 2013-062590, and English-language translation thereof. |
Number | Date | Country | |
---|---|---|---|
20140284802 A1 | Sep 2014 | US |