CN106057654A - 用于金属布线的自对准双重图案化工艺 - Google Patents
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Abstract
本发明揭露用以形成位于导电线之间并连接该导电线的金属布线的自对准双重图案化工艺。实施例包括在介电层上方形成硬掩膜;形成包括位于该硬掩膜上的多个平行线性元件的图案化模板,其中,该硬掩膜暴露于相邻平行线性元件之间;形成覆盖该相邻平行线性元件及它们之间的间隙的部分的块体掩膜;通过该块体掩膜以及定义多条平行线的该图案化模板蚀刻该硬掩膜的暴露部分;移除该块体掩膜以及该图案化模板;在该硬掩膜上方形成截切掩膜,以定义垂直于并连接两条相邻平行线的开口;通过该截切掩膜蚀刻该硬掩膜并移除该截切掩膜;通过该硬掩膜在该介电层中蚀刻凹槽;移除该硬掩膜;以及使用导电材料填充该凹槽。
Description
技术领域
本揭露涉及半导体装置的制造,尤其涉及用以在导电线之间形成金属布线的自对准双重图案化(self-aligned double patterning;SADP)工艺。本揭露尤其适用于7纳米(nm)技术节点及以下的装置。
背景技术
光刻是制造集成电路中所使用的基本工艺。总的来说,光刻包括在材料层或衬底(substrate)上方形成光或辐射敏感材料层,例如光阻。将该辐射敏感材料选择性暴露于由光源(例如深紫外或极紫外源)产生的光,以将由掩膜定义的图案转移至该辐射敏感材料。该辐射敏感材料的暴露层经显影以定义图案化掩膜层。接着,通过该图案化掩膜层在该下方材料层或衬底上可执行各种的工艺操作,例如蚀刻或离子注入工艺。
集成电路制造的目的是在集成电路产品上忠实地复制原始的电路设计。历史上,集成电路产品中所使用的特征尺寸及间距使得通过使用单个图案化光阻掩膜层可形成想要的图案。不过,近年来,装置尺寸及间距已缩小至现有的光刻工具(例如193纳米波长浸没式光刻工具)无法形成具有总体目标图案的所有特征的单个图案化掩膜层的程度。相应地,设计人员已采取包括执行多次曝光以在材料层上定义单个目标图案的技术。一种这样的技术通常被称为多重图案化,例如双重图案化。一般来说,双重图案化是一种曝光方法,其包括将密集的总体目标电路图案分为(也就是划分或分离)两个独立的较不密集图案。接着,通过使用两个独立的掩膜(其中,该掩膜的其中一个用以对该较不密集图案的其中一个成像,且另一个掩膜用以对另一个较不密集图案成像),将该简单的较不密集图案独立印刷于晶圆上。此技术有效降低光刻工艺的复杂性,提高可达到的分辨率并能够印刷更小的特征,否则的话,使用现有的光刻工具是不可能的。光刻-蚀刻-光刻-蚀刻(litho-etch-litho-etch;LELE)是一种这样的多重图案化技术。如图1A中所示,图案无法通过单个掩膜形成,而是被分成两个图案101及103。向各个图案分配不同的颜色,其中,在各种的颜色内都满足设计规则。不过,LELE需要在该两个掩膜之间仔细对准。
业界已开发SADP工艺来克服对准问题。对于SADP,在衬底上形成芯轴(mandrel)图案,在该芯轴的侧表面上沉积间隙壁(spacer)材料,以及移除该芯轴。可使用块体掩膜来隔离将不被蚀刻的部分。由该间隙壁形成的最终图案具有两倍于该芯轴图案的元件。因此,由于使用SADP工艺时可能实现更好的套刻(overlay)控制,因此SADP是制造下一代装置(尤其是此类下一代装置上的金属布线)的具有吸引力的解决方案。常常将由芯轴图案定义的金属线叫作芯轴金属,而将其它金属线叫作非芯轴金属。常常通过两种颜色的金属线来表示芯轴金属与非芯轴金属。在SADP技术中,两种颜色的金属线总是通过间隙壁材料或块体掩膜隔开,以使它们不会重叠。换句话说,金属缝合(metalstitching)在传统SADP技术中是不可能的。
在布局及布线技术中,连接两个毗邻单元的金属线的金属短截线(stub)布线是提升金属布线效率及芯片尺寸缩小以及电路性能的有效技术。在双重图案化技术中,例如20纳米设计的LELE,或者三重图案化中,例如10纳米设计的LELELE,由图1C中的图案107、109、111表示,金属短截线布线需要缝合线来解决相邻线之间的颜色冲突。不过,7纳米设计需要SADP技术,但金属短截线布线不是SADP技术的可选项,因为SADP工艺中不允许缝合。
因此,需要能够在相邻金属线之间形成金属短截线布线的SADP方法。
发明内容
本揭露的一个态样是通过使用SADP技术能够形成金属短截线布线,以提升布线效率、芯片尺寸缩小以及电路性能。
本揭露的额外态样以及其它特征将在下面的说明中阐述,且本领域的普通技术人员在检查下文以后,将在某种程度上清楚该些额外态样以及其它特征,或者该些额外态样以及其它特征可自本揭露的实施中获知。本揭露的优点可如所附权利要求中所特别指出的那样来实现和获得。
依据本揭露,一些技术效果可通过一种方法在某种程度上实现。该方法包括:在介电层上方形成硬掩膜;形成包括设于该硬掩膜上的多个平行线性元件的图案化模板,其中,该硬掩膜暴露于相邻平行线性元件之间;形成覆盖该相邻平行线性元件及该相邻平行线性元件之间的间隙的部分的块体掩膜;通过该块体掩膜以及定义多条平行线的该图案化模板蚀刻该硬掩膜的暴露部分;移除该块体掩膜以及该图案化模板;在该硬掩膜上方形成截切掩膜,以定义垂直于并连接两条相邻平行线的开口;通过该截切掩膜蚀刻该硬掩膜并移除该截切掩膜;通过该硬掩膜在该介电层中蚀刻凹槽;移除该硬掩膜;以及使用导电材料填充该凹槽。
态样包括:通过在该硬掩膜上方形成芯轴,且在各芯轴的相对侧壁上具有间隙壁,以及移除该芯轴来形成该图案化模板。另外的态样包括:该多个平行线性元件均匀地隔开。其它态样包括:通过覆盖与该相邻平行线的其中一条对应的间隙的第一半、以及与该相邻平行线的第二条对应的间隙的第二半来形成该块体掩膜。额外的态样包括:对应该相邻平行线以及该开口在该介电层中蚀刻该凹槽。另一态样包括:该块体掩膜包括第一光阻掩膜,且该截切掩膜包括第二光阻掩膜。又一态样包括:通过该块体掩膜蚀刻该硬掩膜层发生于所述通过该截切掩膜蚀刻该硬掩膜层之前。另一态样包括:形成该截切掩膜还定义垂直于该两条相邻平行线并位于该两条相邻平行线的端部的功率线。其它态样包括:使用铜或钨填充该凹槽。额外态样包括:该相邻平行线位于相邻单元中。
本揭露的另一态样是一种方法,包括:在介电层上方形成硬掩膜;在该硬掩膜上方形成芯轴,在各芯轴的相对侧壁上具有间隙壁,该间隙壁在其之间定义多条平行线;移除该芯轴;形成覆盖该多条平行线的部分的块体掩膜;蚀刻通过该块体掩膜及该间隙壁暴露的该硬掩膜的部分;移除该块体掩膜以及该间隙壁;在该硬掩膜上方形成截切掩膜,以定义垂直于并连接该多条平行线的第一及第二线的开口;通过该截切掩膜蚀刻该硬掩膜;移除该截切掩膜;在该介电层中蚀刻凹槽,该凹槽对应该多条平行线以及该开口;移除该硬掩膜;以及使用导电材料填充该凹槽。
态样包括:该块体掩膜包括第一光阻掩膜,且该截切掩膜包括第二光阻掩膜。另外的态样包括:该相邻平行线位于相邻单元中。另一态样包括:通过该块体掩膜蚀刻该硬掩膜层发生于所述通过该截切掩膜蚀刻该硬掩膜层之前。其它态样包括:形成该截切掩膜还定义垂直于该平行线并位于该平行线的端部的功率线。额外态样包括:形成该块体掩膜包括覆盖与该相邻平行线的其中一条对应的间隙的第一半部分、以及与该相邻平行线的第二条对应的间隙的第二半部分。另外的态样包括:该截切掩膜形成于与该平行线对应的该间隙的该第一与第二半部分之间。另一态样包括:该芯轴均匀隔开。额外态样包括:该芯轴包括一维图案。
本揭露的又一态样是一种方法,包括:在介电层上方形成硬掩膜;在该硬掩膜上方形成芯轴,在各芯轴的相对侧壁上具有间隙壁,该间隙壁在其之间定义多条平行线;移除该芯轴;形成覆盖该多条平行线的部分的光阻块体掩膜;蚀刻通过该块体掩膜及该间隙壁暴露的该硬掩膜的部分;移除该第一光阻块体掩膜以及该间隙壁;在该光阻硬掩膜上方形成光阻截切掩膜,以定义:垂直于并连接该多条平行线的第一及第二线的开口,以及垂直于该平行线并位于该平行线的端部的功率线;通过该截切掩膜蚀刻该硬掩膜;移除该截切掩膜;对应该多条平行线、该开口以及功率线在该介电层中蚀刻凹槽;移除该硬掩膜;以及使用导电材料填充该凹槽。
本领域的技术人员从下面的详细说明中将很容易了解额外态样以及技术效果,在该详细说明中,通过说明用以执行本揭露的最佳模式来简单说明本揭露的实施例。本领域的技术人员将意识到,本揭露支持其它且不同的实施例,且其若干细节支持在各种显而易见的方面的修改,所有这些都不背离本揭露。相应地,附图及说明将被看作说明性质而非限制性质。
附图说明
附图中的图形示例显示(而非限制)本揭露,附图中类似的附图标记表示类似的元件,其中:
图1A及图1B分别示意显示LELE及LELELE的传统布局,以及图1C示意显示通过SADP形成的传统金属线布局;
图2A至图2F示意显示依据示例实施例利用SADP形成具有例如金属短截线布线的金属互连结构的金属线的流程的剖切视图;
图3A及图3B示意显示依据示例实施例结合SADP使用截切掩膜来形成例如金属短截线布线的互连结构的工艺步骤的顶部平面视图;以及
图4示意显示依据示例实施例由图2A至图2F以及图3A及图3B的工艺形成的金属线及互连结构的额外顶部平面视图。
具体实施方式
在下面的说明中,出于解释目的,阐述许多具体细节来提供有关示例实施例的充分理解。不过,应当很清楚,可在不具有这些具体细节或者具有等同布置的情况下实施示例实施例。在其它例子中,以方块图形式显示已知的结构及装置,以避免不必要地模糊示例实施例。此外,除非另外指出,否则说明书及权利要求中所使用的表示组分的量、比例及数值属性,反应条件等的所有数字将被理解为通过术语“大约”在所有情况下都被修改。
本揭露处理并解决于使用SADP时伴随的无法在不同颜色的导电线之间形成金属凸起或短截线布线的问题。依据本揭露的实施例的方法包括在SADP工艺期间在施加块体掩膜之后施加截切掩膜,以在不同颜色的导电线之间形成例如金属短截线布线的互连结构并有效解决相邻线之间的颜色冲突。
本领域的技术人员从下面的详细说明中将很容易了解其它态样、特征以及技术效果,在该详细说明中,通过说明所考虑的最佳模式来简单地显示并说明优选实施例。本揭露支持其它且不同的实施例,且其若干细节支持在各种显而易见的方面的修改。相应地,附图及说明将被看作说明性质而非限制性质。
请参照图2A,其显示在介电层203的表面上形成硬掩膜201。介电层203由例如低k介电材料(具有约2.7或更高的介电常数的介电材料)或者超低k(ultra-low-k;ULK)材料(具有约2.5或更低的介电常数的介电材料)组成。硬掩膜201由例如氮化硅、旋涂碳等组成。
通过首先形成设于硬掩膜201上的多个平行元件205来在硬掩膜201上方形成图案化模板。该平行元件包括例如以均匀隔开的一维图案形成于硬掩膜层201上方的芯轴,硬掩膜201的部分暴露于相邻芯轴205之间。在该图案化模板下方可形成其它层,例如抗反射涂层(anti-reflective coating;ARC)(出于说明方便未显示)。如图2B所示,在平行元件205上方设置间隙壁层207。间隙壁层可由例如二氧化硅形成,并通过沉积工艺沉积于平行元件205上方。
接着,执行非等向性蚀刻工艺,例如干式蚀刻工艺,以在各平行元件205的相对侧壁上定义间隙壁209。接着,执行蚀刻工艺,以相对该间隙壁及硬掩膜201选择性移除平行元件205。该侧间隙壁的间距是该芯轴或平行元件的间距的两倍。如图2C所示,间隙壁209定义暴露硬掩膜层201的开口。图2C显示形成块体掩膜211(例如第一光阻掩膜)以后的已完成图案化模板。块体掩膜211覆盖相邻平行线性元件以及该相邻平行线性元件(也就是间隙壁)209之间的间隙的部分。
请参照图2D,通过间隙壁209及块体掩膜211非等向性蚀刻硬掩膜201,以部分图案化该硬掩膜层201。接着,可执行灰化工艺以移除块体掩膜211,且可执行蚀刻工艺以相对硬掩膜层201选择性移除间隙壁209。此操作导致形成部分图案化的硬掩膜层201,其包括多个平行线段开口213,其暴露部分图案化的硬掩膜层201下面的介电层203的相应下方部分。开口213与将在硬掩膜201下面的介电层203中形成的平行导电线的位置对应。
现在请参照图3A及图3B,其显示本申请的示例工艺的顶部平面视图。尤其,在上述用以移除块体掩膜211的该灰化工艺之前,图3A显示覆盖相邻间隙213的部分的块体掩膜211。在此非限制性例子中,块体掩膜211覆盖相邻平行间隙213的其中一个的第一半以及第二相邻间隙213的第二半。要注意的是,间隙213之间是位于间隙壁209下方且因此未被蚀刻的硬掩膜层201的部分。块体掩膜的位置沿该平行间隙处于端部、中间或是另一位置是取决于预期的图案布局。要注意的是,图3A及图3B中所示的相邻间隙213与将要在介电层203中形成的两条平行导电线对应。
图3B显示在部分图案化的硬掩膜层201上方形成具有开口301的截切掩膜(例如第二光阻)以后的硬掩膜201。该截切掩膜设于硬掩膜201上方,以定义垂直于并连接两个相邻平行间隙213的开口301,从而形成凸起。该截切掩膜覆盖先前在部分图案化的硬掩膜层201中形成的开口,并包含暴露与将要在两条平行导线之间的介电层203中形成的垂直线的位置对应的位置处的硬掩膜层201的开口。或者,可不具有覆盖间隙213的部分的块体掩膜211。接着,该截切掩膜可具有与用以连接相邻单元的平行线的位置对应的开口。此垂直线开口与在两条平行导电线之间形成的导电互连(也就是金属短截线布线或“缝合线”)的位置对应。见例如图4中的缝合线401。该截切掩膜也可经形成以定义位于该导电线的一个或多个端部的一条或多条功率线/轨。
图4显示标准设计单元阵列,其包括在该阵列的两个不同单元的边缘处所形成的导电线之间形成的多条短截线布线。在该些导电线的端部形成功率线/轨403。在图4中,其中一条短截线布线401连接两条导电线405及407,该两条导电线分别形成于两个不同的单元409及411中。此例中的第二短截线布线401连接分别形成于两个不同的单元417及419中的两条导电线413及415。导电线413及417表示芯轴线(并以第一颜色表示),且导电线405表示非芯轴线(与415以第二颜色表示)。所有该导电线都使用金属例如铜或钨填充。
现在复请参照图2E,其显示通过该截切掩膜(图3B)执行蚀刻工艺并已移除该截切掩膜以后的完全图案化的硬掩膜层201的剖切视图。完全图案化的硬掩膜层201包括介电层203中的线开口或凹槽215,以及与该截切掩膜中的该开口对应的垂直线开口(剖切视图中未显示)。通过完全图案化的硬掩膜层201中的该些开口执行非等向性蚀刻工艺,以蚀刻介电层203,从而在其中定义相应凹槽215。
执行一个或多个沉积工艺,以使用导电材料217过填充(over-fill)凹槽215。接着,如图2F所示,执行平坦化工艺,以移除多余的导电材料217以及完全图案化的硬掩膜层201。导电材料217可包括多个层,例如用以防止金属迁移进入介电层203的一个或多个阻挡层(例如Ta(钽)、TaN(氮化钽)、TiN(氮化钛)等),金属晶种层(例如铜),以及金属填充材料(例如铜或钨)。
本揭露的实施例可实现数个技术效果,例如结合SADP工艺形成缝合线及凸起。依据本揭露的实施例形成的装置适于各种工业应用,例如微处理器、智能电话、移动电话、蜂窝手机、机顶盒、DVD记录器及播放器、汽车导航、打印机及周边设备、网络及电信设备、游戏系统,以及数字相机。因此,尤其是对于7纳米技术节点以及以下,通过自对准双重图案化工艺,本揭露在任意各种类型的高度集成半导体装置的制造中享有工业适用性。
在前面的说明中,参照本揭露的具体示例实施例来说明本揭露。不过,显然,可对其作各种修改及变更,而不背离如权利要求中所阐述的本揭露的较广泛的精神及范围。相应地,说明书及附图将被看作说明性质而非限制性质。要理解的是,本揭露能够使用各种其它组合及实施例,且支持在这里所表示的发明性概念的范围内的任意修改或变更。
Claims (20)
1.一种方法,包括:
在介电层上方形成硬掩膜;
形成包括设于该硬掩膜上的多个平行线性元件的图案化模板,其中,该硬掩膜暴露于相邻平行线性元件之间;
形成覆盖该相邻平行线性元件及该相邻平行线性元件之间的间隙的部分的块体掩膜;
通过该块体掩膜以及定义多条平行线的该图案化模板蚀刻该硬掩膜的暴露部分;
移除该块体掩膜以及该图案化模板;
在该硬掩膜上方形成截切掩膜,以定义垂直于并连接两条相邻平行线的开口;
通过该截切掩膜蚀刻该硬掩膜并移除该截切掩膜;
通过该硬掩膜在该介电层中蚀刻凹槽;
移除该硬掩膜;以及
使用导电材料填充该凹槽。
2.如权利要求1所述的方法,其中,形成该图案化模板包括:
在该硬掩膜上方形成芯轴,在各芯轴的相对侧壁上具有间隙壁,以及移除该芯轴。
3.如权利要求1所述的方法,其中,该多个平行线性元件均匀地隔开。
4.如权利要求1所述的方法,其中,形成该块体掩膜包括覆盖与该相邻平行线的其中一条对应的间隙的第一半、以及与该相邻平行线的第二条对应的间隙的第二半。
5.如权利要求1所述的方法,其中,在该介电层中蚀刻该凹槽对应该相邻平行线以及该开口。
6.如权利要求1所述的方法,其中,该块体掩膜包括第一光阻掩膜,且该截切掩膜包括第二光阻掩膜。
7.如权利要求1所述的方法,其中,通过该块体掩膜蚀刻该硬掩膜层发生于所述通过该截切掩膜蚀刻该硬掩膜层之前。
8.如权利要求1所述的方法,其中,形成该截切掩膜还定义垂直于该两条相邻平行线并位于该两条相邻平行线的端部的功率线。
9.如权利要求1所述的方法,其中,填充该凹槽包括使用铜或钨填充该凹槽。
10.如权利要求1所述的方法,其中,该相邻平行线位于相邻单元中。
11.一种方法,包括:
在介电层上方形成硬掩膜;
在该硬掩膜上方形成芯轴,在各芯轴的相对侧壁上具有间隙壁,该间隙壁在其之间定义多条平行线;
移除该芯轴;
形成覆盖该多条平行线的部分的块体掩膜;
通过该块体掩膜及该间隙壁蚀刻该硬掩膜的暴露部分;
移除该块体掩膜以及该间隙壁;
在该硬掩膜上方形成截切掩膜,以定义垂直于并连接该多条平行线的第一及第二线的开口;
通过该截切掩膜蚀刻该硬掩膜;
移除该截切掩膜;
在该介电层中蚀刻凹槽,该凹槽对应该多条平行线以及该开口;
移除该硬掩膜;以及
使用导电材料填充该凹槽。
12.如权利要求11所述的方法,其中,该块体掩膜包括第一光阻掩膜,且该截切掩膜包括第二光阻掩膜。
13.如权利要求11所述的方法,其中,该相邻平行线位于相邻单元中。
14.如权利要求11所述的方法,其中,通过该块体掩膜蚀刻该硬掩膜层发生于所述通过该截切掩膜蚀刻该硬掩膜层之前。
15.如权利要求11所述的方法,其中,形成该截切掩膜还定义垂直于该平行线并位于该平行线的端部的功率线。
16.如权利要求11所述的方法,其中,形成该块体掩膜包括覆盖与该相邻平行线的其中一条对应的间隙的第一半部分、以及与该相邻平行线的第二条对应的间隙的第二半部分。
17.如权利要求16所述的方法,其中,该截切掩膜形成于与该平行线对应的该间隙的该第一与第二半部分之间。
18.如权利要求11所述的方法,其中,该芯轴均匀隔开。
19.如权利要求11所述的方法,其中,该芯轴包括一维图案。
20.一种方法,包括:
在介电层上方形成硬掩膜;
在该硬掩膜上方形成芯轴,在各芯轴的相对侧壁上具有间隙壁,该间隙壁在其之间定义多条平行线;
移除该芯轴;
形成覆盖该多条平行线的部分的光阻块体掩膜;
通过该块体掩膜及该间隙壁蚀刻该硬掩膜的暴露部分;
移除该第一光阻块体掩膜以及该间隙壁;
在该光阻硬掩膜上方形成光阻截切掩膜,以定义:
垂直于并连接该多条平行线的第一及第二线的开口,以及
垂直于该平行线并位于该平行线的端部的功率线;
通过该截切掩膜蚀刻该硬掩膜;
移除该截切掩膜;
对应该多条平行线、该开口以及功率线在该介电层中蚀刻凹槽;
移除该硬掩膜;以及
使用导电材料填充该凹槽。
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