Suspended airbridges are generally used in semiconductor devices, such as monolithic microwave integrated circuits (MMICs), in order to isolate and reduce parasitic capacitance between conductors, such as gate, source and drain electrodes. Gallium arsenide (GaAs) semiconductor devices, in particular, may include airbridges formed of conductive material applied by electro-deposition or electroplating techniques, such as plated gold (Au). For example, the airbridges may extend from pad areas to various components of the semiconductor devices. The airbridges are typically covered by an insulating layer, such as silicon nitride (SiNx), for isolating and protecting the semiconductor devices from environmental conditions, such as temperature, moisture, debris, and the like.
Conventional fabrication techniques include applying an adhesion layer to the plated conductive material of an airbridge prior to application of the insulating layer. Generally, the adhesion layer applied to the plated conductive material can be applied by a variety of techniques, such as evaporation. Conductive adhesion materials are typically patterned using lithography and either etch or lift-off processes, which require corresponding processing steps. Also, insulating adhesion layer materials provide generally poor adhesion characteristics, often resulting in delamination (e.g., nitride delamination) of the insulating layer from the airbridge. Such delamination increases the risk of operational failures and raises field reliability issues, as well as increases in-line and assembly scrap.
In a representative embodiment, a method of forming a device having an airbridge on a substrate includes forming a plated conductive layer of the airbridge over at least a photoresist layer on a portion of the substrate, the plated conductive layer defining a corresponding opening for exposing a portion of the photoresist layer. The method further includes undercutting the photoresist layer to form a gap in the photoresist layer beneath the plated conductive layer at the opening, and forming an adhesion layer on the plated conductive layer and the exposed portion of the photoresist layer, the adhesion layer having a break at the gap beneath the plated conductive layer. The photoresist layer and a portion of the adhesion layer formed on the exposed portion of the photoresist layer is removed, which includes etching the photoresist layer through the break in the adhesion layer. An insulating layer is formed on at least the adhesion layer, enhancing adhesion of the insulating layer to the plated conductive layer.
In another representative embodiment, a method is provided for forming an airbridge extending from a conductive area of a gallium arsenide (GaAs) semiconductor device. The method includes applying a first photoresist layer on a substrate, with or without a device, and developing the first photoresist layer to form a first photoresist pattern; applying a conductive lower layer on the first photoresist layer; applying a conductive seed layer on the conductive lower layer; applying a second photoresist layer on the conductive seed layer, and etching the second photoresist layer to form a second photoresist pattern; applying a plated gold layer on the conductive seed layer using an electroplating process; removing the second photoresist pattern using a develop or etching process to form an opening in the plated gold layer corresponding to the airbridge of the semiconductor device, the opening exposing a portion of the conductive seed layer; removing the exposed portion of the conductive seed layer, exposing a portion of the first photoresist pattern within the opening in the plated gold layer; partially etching the exposed portion of the first photoresist pattern using oxygen plasma, the partial etching undercutting the photoresist layer to form a gap between the plated gold layer and the first photoresist pattern at the opening in the plated gold layer; applying an adhesion layer on the plated gold layer and the exposed portion of the first photoresist pattern, the adhesion layer having a break at the gap between the plated gold layer and the first photoresist pattern; removing the first photoresist pattern using a solvent applied to the first photoresist pattern through the break in the adhesion layer, the solvent lifting off a portion of the adhesion layer on the exposed portion of the first photoresist pattern; and applying an insulating layer on the adhesion layer to enhance adhesion of the insulating layer to the plated gold layer.
In another representative embodiment, a semiconductor device includes a device pattern formed on a semiconductor substrate, a seed layer formed on the device pattern, and an airbridge formed on the seed layer, where the airbridge includes a plated conductive material and defines an opening exposing a portion of the device pattern. An adhesion layer is formed on the airbridge layer and extends over at least a portion of sidewalls of the opening defined by the airbridge. An insulating layer is formed on the adhesion layer, such that the adhesion layer enhances adhesion of the insulating layer to the plated conductive material of the airbridge.
The example embodiments are best understood from the following detailed description when read with the accompanying drawing figures. It is emphasized that the various features are not necessarily drawn to scale. In fact, the dimensions may be arbitrarily increased or decreased for clarity of discussion. Wherever applicable and practical, like reference numerals refer to like elements.
In the following detailed description, for purposes of explanation and not limitation, representative embodiments disclosing specific details are set forth in order to provide a thorough understanding of the present teachings. However, it will be apparent to one having ordinary skill in the art having had the benefit of the present disclosure that other embodiments according to the present teachings that depart from the specific details disclosed herein remain within the scope of the appended claims. Moreover, descriptions of well-known apparatuses and methods may be omitted so as to not obscure the description of the representative embodiments. Such methods and apparatuses are clearly within the scope of the present teachings.
Generally, it is understood that the drawings and the various elements depicted therein are not drawn to scale. Further, relative terms, such as “above,” “below,” “top,” “bottom,” “upper,” “lower,” “left,” “right,” “vertical” and “horizontal,” are used to describe the various elements' relationships to one another, as illustrated in the accompanying drawings. It is understood that these relative terms are intended to encompass different orientations of the device and/or elements in addition to the orientation depicted in the drawings. For example, if the device were inverted with respect to the view in the drawings, an element described as “above” another element, for example, would now be “below” that element. Likewise, if the device were rotated 90 degrees with respect to the view in the drawings, an element described as “vertical,” for example, would now be “horizontal.”
Referring to
Airbridges 140a and 140b are formed of plated conductive material, such as plated Au. The airbridges 140a and 140b extend from the source and drain electrodes 114 and 116, respectively, and provide corresponding pad areas for connection of the device 100 to external circuits. The airbridges 140a and 140b are connected to the source and drain electrodes 114 and 116, as well as the gate electrode (not shown), via a conductive seed layer 130. In the depicted illustrative configuration, the airbridges 140a and 140b define opening 142 and air space 148, in which the transistor 119 is situated.
An adhesion layer 150 is applied to surfaces of the airbridges 140a and 140b. In various embodiments, the adhesion layer 150 may be formed of a conductive adhesion material, such as titanium (Ti) or tantalum (Ta), or an insulating adhesion material, such as titanium oxide (TiOx). As shown, a side portion 150a of the adhesion layer 150 adheres to at least a portion of side walls in the opening 142. A second insulating layer 160 is formed on the adhesion layer 150 and the first insulating layer 122, thereby protecting the airbridges 140a and 140b and the gate electrode, the source electrode 114 and the drain electrode 116 of the transistor 119. According to various embodiments, the adhesion layer 150 improves adhesion characteristics between the airbridges 140a and 140b and the insulating material of the second insulating layer 160. This reduces the possibility of delamination and generally improves field reliability of the device 100.
According to various embodiments, the device 100 may be fabricated using various techniques compatible with microfabrication and semiconductor processes. A non-limiting example of a fabrication process directed to representative device 100 is discussed below with reference to FIGS. 2 and 3A-3J. In the depicted example, it is assumed that the device 100 being fabricated is a GaAs based device. However, it is understood that alternative embodiments may include fabrication of other types of devices, such as silicon based devices, in the case of CMOS or MEMS applications, for example, without departing from the scope of the present teachings.
In step S211 of
In step S212, a first photoresist pattern 125 is formed on the substrate 110 and device(s) (e.g., including gate pattern 112), and the first insulating pattern 122, as shown in
In step S213, a conductive seed layer 130 is formed on the first insulating pattern 122 and the exposed surfaces of the source and drain electrodes 114 and 116, also shown in
In an embodiment, the conductive seed layer 130 is formed on a conductive lower layer 131, which may be formed of a different material. That is, the conductive lower layer 131 is formed on the photoresist pattern 125, the first insulating pattern 122 and the exposed surfaces of the source and drain electrodes 114 and 116, and the conductive seed layer 130 is formed on the conductive lower layer 131. The conductive lower layer may be formed of titanium tungsten (TiW), for example, applied using evaporation, sputtering, or CVD processes. The conductive lower layer of TiW may have a thickness of about 0.1 μm to about 10 μm, and the conductive seed layer of plated Au may have a thickness of about 0.01 μm to about 0.5 μm, for example. Of course, the number of conductive layers and/or the materials forming the conductive layers may vary, without departing from the scope of the present teachings. The previous baking of the first photoresist pattern 125, discussed above, prevents the first photoresist pattern 125 from being lifted, or otherwise damaged during application of the conductive seed layer 130 and/or the conductive lower layer 131. Also, prior to applying the conductive seed layer 130 and/or the conductive lower layer 131, the surfaces of the first insulating pattern 122 and the source and drain electrodes 114 and 116 may be prepared, e.g., by performing a cleaning process, such as de-scum.
A second photoresist pattern 135 is formed on the conductive seed layer 130 in step S214, as shown in
In step S215, conductive airbridge layer 141 is formed on the conductive seed layer 130, shown in
The second photoresist pattern 135 is removed in step S216, as shown in
The exposed portion of the conductive seed layer 130 (and the conductive lower layer 131) is removed in step S217, exposing a portion of the top surface of the first photoresist pattern 125 within the opening 142, as shown in
In step S218, a portion of first photoresist pattern 125 is undercut to form a gap 124 in the first photoresist pattern 125 beneath the conductive airbridge layer 141 (as well as the conductive seed layer 130 and the conductive lower layer 131), substantially around a periphery of the opening 142, as shown in
In step S219, an adhesion layer 150 is formed on a top surface of the conductive airbridge layer 141 and the exposed portion of the first photoresist pattern 125 within the opening 142, as shown in
Notably, a side portion 150a of the adhesion layer 150 adheres to the side walls of the opening 142, although the side portion 150a may be generally thinner than top coverage of the adhesion layer 150. Also, the side portion 150a may not necessarily cover the entirety of the side walls in the opening 142. A bottom portion 150b of the adhesion layer 150 is applied to the exposed portion of the first photoresist pattern 125 within the opening 142. A break 153 is formed in the adhesion layer 150 at the gap 124, substantially separating the side portion 150a from the bottom portion 150b of the adhesion layer 150. In other words, the adhesion layer 150 is not continuously formed throughout the opening 142.
The first photoresist pattern 125 is removed in step S220, as shown in
Removal of the first photoresist pattern 125 and the bottom portion 150b of the adhesion layer 150 exposes the first insulating pattern 122 of the transistor 119 within a resulting air space 148, via the opening 142. Also, the conductive airbridge layer 141 forms airbridges 140a and 140b extending from the source and drain electrodes 114 and 116, respectively, over the resulting air space 148. The airbridges 140a and 140b may be connected or serve as pad areas for the source and drain electrodes 114 and 116, respectively.
In step S221, second insulating layer 160 is formed on the adhesion layer 150, portions of the conductive lower layer 131, and the first insulating pattern 122, resulting in the device 100, as shown in
According to various embodiments, a semiconductor device having an improved adhesion between an insulating layer and a plated conductive material of an airbridge, resulting in a more robust semiconductor device. This enables operation of the semiconductor device in harsher environments, and otherwise increases reliability and manufacturing efficiency of the semiconductor device. In addition, conventional techniques for applying conductive adhesion materials, such as titanium, are typically patterned using lithography and either etch or lift-off processes, as mentioned above. However, the various embodiments provide a self-aligned process that does not require a lithography step (or subsequent etching or lift-off), and is therefore less expensive and less complicated, particularly with respect to raised airbridge structures.
The various components, materials, structures and parameters are included by way of illustration and example only and not in any limiting sense. In view of this disclosure, those skilled in the art can implement the present teachings in determining their own applications and needed components, materials, structures and equipment to implement these applications, while remaining within the scope of the appended claims.
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