TWI536452B - Method of fabricating dielectric layer and shallow trench isolation - Google Patents
Method of fabricating dielectric layer and shallow trench isolation Download PDFInfo
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本發明係關於一種介電層的製作方法,尤指一種可適用於淺溝渠隔離之介電層的表面處理製程。 The invention relates to a method for fabricating a dielectric layer, in particular to a surface treatment process applicable to a dielectric layer of shallow trench isolation.
在半導體製程中,為了使晶片上各個電子元件之間擁有良好的隔離,以避免元件相互干擾而產生短路現象,一般採用區域氧化法(localized oxidation isolation,LOCOS)或是淺溝渠隔離(shallow trench isolation,STI)方法來進行隔離與保護。由於LOCOS製程中產生的場氧化層(field oxide)所佔據晶片的面積太大,且生成過程會伴隨鳥嘴(bird’s beak)現象的發生,因此,具有小尺寸隔離線寬、明確之主動區劃分、均勻的隔離區深度、尺寸可調整(scalable)以及絕佳的隔離區平坦架構等優點的淺溝渠隔離法,已漸漸成為目前半導體元件隔離技術的主流。 In the semiconductor process, in order to have good isolation between the various electronic components on the wafer to avoid short-circuit phenomenon caused by mutual interference of components, generally used localized oxidation isolation (LOCOS) or shallow trench isolation (shallow trench isolation) , STI) method for isolation and protection. Since the area of the wafer occupied by the field oxide generated in the LOCOS process is too large, and the generation process is accompanied by the occurrence of a bird's beak phenomenon, it has a small-sized isolation line width and a clear active area division. The shallow trench isolation method, which has the advantages of uniform isolation depth, scalable size, and excellent isolation flat structure, has gradually become the mainstream of semiconductor component isolation technology.
淺溝渠隔離的製作方法一般而言是在晶片表面的各元件間製作一溝槽,並填入絕緣物質以產生電性隔離的效果。然而,隨著半導體朝向微細化尺寸以及高積集度(high integration)的方向發展,當利用化學氣相沉積法(chemical vapor deposition,CVD)於半導體晶片表面形成一層介電層並填滿溝槽時,非常容易因為溝槽之過大的深寬比(high aspect ratio),而在溝槽頂部的轉角部份發生懸突(over hang) 現象,使得形成的淺溝渠隔離中具有孔洞(void)。 The method of fabricating shallow trench isolation is generally to create a trench between the components on the surface of the wafer and fill the insulating material to produce an electrical isolation effect. However, as semiconductors move toward miniaturization and high integration, a dielectric layer is formed on the surface of the semiconductor wafer by chemical vapor deposition (CVD) and fills the trench. At the time, it is very easy because of the excessive aspect ratio of the trench, and the overhang of the corner portion at the top of the trench occurs. The phenomenon is such that there is a void in the shallow trench isolation formed.
此外,於習知製造半導體元件的過程中,會進行多次的蝕刻及清洗製程,例如:為了移除各電晶體之頂蓋層與硬罩幕層所進行的蝕刻製程、間隙壁形成之蝕刻與其後所進行的清洗製程、主動區中之源極/汲極形成之後所進行的清洗製程、金屬矽化物層形成之前所進行的預清洗製程、以及最後移除未反應完全之金屬層的蝕刻製程等,而在進行這些蝕刻製程與清洗製程時,往往會對裸露之淺溝渠隔離造成傷害,使淺溝渠隔離表面產生凹陷(recess),或在基底與淺溝渠隔離的交界處形成空隙。 In addition, in the process of manufacturing a semiconductor device, a plurality of etching and cleaning processes are performed, for example, an etching process for removing the cap layer and the hard mask layer of each transistor, and etching of the spacer layer. The subsequent cleaning process, the cleaning process performed after the source/drain formation in the active region, the pre-cleaning process performed before the formation of the metal telluride layer, and finally the etching of the unreacted metal layer is removed. Processes, etc., while performing these etching processes and cleaning processes, tend to cause damage to the exposed shallow trenches, causing recesses in the shallow trench isolation surface, or forming voids at the interface between the substrate and the shallow trenches.
因此,如何改善淺溝渠隔離製程以避免上述缺陷的發生進而避免漏電流的形成,實為相關技術者所欲改進之課題。 Therefore, how to improve the shallow trench isolation process to avoid the occurrence of the above defects and avoid the formation of leakage current is a problem that the related art desires to improve.
本發明之目的之一在於提供介電層以及淺溝渠隔離的製作方法,以避免介電層以及淺溝渠隔離在製作過程中或後續製程中發生缺陷。 One of the objects of the present invention is to provide a method for fabricating a dielectric layer and shallow trench isolation to avoid defects in the dielectric layer and shallow trench isolation during fabrication or subsequent processing.
本發明之一較佳實施例係提供一種製作介電層的方法,其步驟如下。首先,形成一介電層於一基底上,且對介電層進行一化學機械研磨(chemical mechanical polishing,CMP)製程。接著,在進行化學機械研磨製程後,對介電層進行一表面處理製程,其中表面處理製 程包括通入一氧(oxygen)電漿。 A preferred embodiment of the present invention provides a method of fabricating a dielectric layer, the steps of which are as follows. First, a dielectric layer is formed on a substrate, and a chemical mechanical polishing (CMP) process is performed on the dielectric layer. Then, after performing the chemical mechanical polishing process, a surface treatment process is performed on the dielectric layer, wherein the surface treatment process is performed. The process involves the introduction of an oxygen plasma.
本發明之另一較佳實施例係提供一種製作淺溝渠隔離的方法,其步驟如下。首先,形成至少一溝槽於一基底中,且形成一介電層填入溝槽。隨後,對介電層進行一化學機械研磨製程製程。接著,在進行化學機械研磨製程後,對介電層進行一表面處理製程,其中表面處理製程包括通入一氧電漿。 Another preferred embodiment of the present invention provides a method of making shallow trench isolation, the steps of which are as follows. First, at least one trench is formed in a substrate, and a dielectric layer is formed to fill the trench. Subsequently, a chemical mechanical polishing process is performed on the dielectric layer. Next, after performing the chemical mechanical polishing process, a surface treatment process is performed on the dielectric layer, wherein the surface treatment process includes passing an oxygen plasma.
本發明係使用流動式化學氣相沈積(flowable chemical vapor deposition,FCVD)製程形成介電層,使介電層可完整覆蓋基底且填滿溝槽,而不產生孔洞或空隙,達到良好溝槽填充(gap filling)效果。此外,對介電層之表面進行氧電漿處理製程,可使氧自由基(radical)造成介電層之表面的懸空鍵(dangling bond)之鍵結(crosslink),以提高介電層之緻密度,避免介電層於後續的蝕刻及清洗製程中受到損傷,有助於維持介電層的結構完整性及絕緣效果。 The invention uses a flow chemical vapor deposition (FCVD) process to form a dielectric layer, so that the dielectric layer can completely cover the substrate and fill the trench without generating holes or voids, thereby achieving good trench filling. (gap filling) effect. In addition, the oxygen plasma treatment process is performed on the surface of the dielectric layer, so that oxygen radicals cause a dangling bond of the surface of the dielectric layer to improve the density of the dielectric layer. To avoid damage to the dielectric layer during subsequent etching and cleaning processes, to help maintain the structural integrity and insulation of the dielectric layer.
為使熟習本發明所屬技術領域之一般技藝者能更進一步了解本發明,下文特列舉本發明之較佳實施例,並配合所附圖式,詳細說明本發明的構成內容及所欲達成之功效。 The present invention will be further understood by those of ordinary skill in the art to which the present invention pertains. .
請參考第1圖至第6圖。第1圖至第6圖繪示了本發明之一較佳實施例之製作淺溝渠隔離的方法的示意圖。如第1圖所示,先於基 底10上依序以例如熱氧化製程形成一矽氧層(silicon oxide)12以及例如以低壓化學氣相沈積(low pressure chemical vapor deposition,LPCVD)製程形成一氮矽層(silicon nitride)14。基底10例如是一矽基底、一含矽基底、一三五族覆矽基底(例如GaN-on-silicon)、一石墨烯覆矽基底(graphene-on-silicon)或一矽覆絕緣(silicon-on-insulator,SOI)基底等半導體基底。其中矽氧層12係為墊氧化層(pad oxide),可用以做為氮矽層14的應力緩衝層,增加氮矽層14對基底的附著力;而氮矽層14可用來當作後續蝕刻的硬遮罩(hard mask)或化學機械研磨(CMP)製程的停止層。形成上述各個膜層的製程不限於上面列舉的熱氧化製程與低壓化學氣相沈積製程,也可以是濕式化學氧化製程、其他化學氣相沈積製程等。 Please refer to Figures 1 to 6. 1 to 6 are schematic views showing a method of fabricating shallow trench isolation in accordance with a preferred embodiment of the present invention. As shown in Figure 1, prior to the base A silicon oxide 12 is formed on the bottom 10 by, for example, a thermal oxidation process, and a silicon nitride 14 is formed, for example, by a low pressure chemical vapor deposition (LPCVD) process. The substrate 10 is, for example, a substrate, a germanium-containing substrate, a tri-five-layer overlying substrate (eg, GaN-on-silicon), a graphene-on-silicon or a silicon-on-insulator (silicon- On-insulator, SOI) A semiconductor substrate such as a substrate. The silicon oxide layer 12 is a pad oxide layer, which can be used as a stress buffer layer of the nitrogen germanium layer 14 to increase the adhesion of the nitrogen germanium layer 14 to the substrate; and the nitrogen germanium layer 14 can be used as a subsequent etching. A hard mask or a stop layer of a chemical mechanical polishing (CMP) process. The process for forming each of the above-mentioned film layers is not limited to the above-described thermal oxidation process and low-pressure chemical vapor deposition process, and may be a wet chemical oxidation process, another chemical vapor deposition process, or the like.
接著,如第2圖所示,利用微影(photolithography)及蝕刻(etching)等製程,在基底10之一預定區域內形成至少一溝槽R,並使溝槽R穿過矽氧層12以及氮矽層14深入基底10至一預定深度。舉例來說,先於氮矽層14上形成一光阻層(圖未示)並進行一微影製程,以形成一圖案化(patterned)光阻層(圖未示),且圖案化光阻層可約略定義出溝槽(recess)R的圖案(pattern),然後,以圖案化光阻層作為一圖案化遮罩層,進行一蝕刻製程例如反應性離子蝕刻(reactive-ion-etching,RIE)製程,移除部分氮矽層14、部分矽氧層12與部分基底10,以形成溝槽R於基底10中,隨後,去除圖案化光阻層。此外,也可預先將圖案化光阻層的圖案轉移至氮矽層14與矽氧層12形成暴露部分基底10的開口後,再去除圖案化光阻層, 並以氮矽層14與矽氧層12共同作為一圖案化遮罩層,進行蝕刻製程來移除部分基底10,以形成溝槽R。其中,定義溝槽R圖案的圖案化遮罩層以及形成溝槽R的方式不以此為限,此外,在基底10中形成溝槽R之後,亦可以選擇性對圖案化遮罩層進行一退縮(pull back)製程,以調整圖案化遮罩層的形狀。 Next, as shown in FIG. 2, at least one trench R is formed in a predetermined region of the substrate 10 by a process such as photolithography and etching, and the trench R is passed through the silicon oxide layer 12 and The yttrium nitride layer 14 penetrates the substrate 10 to a predetermined depth. For example, a photoresist layer (not shown) is formed on the ytterbium layer 14 and a lithography process is performed to form a patterned photoresist layer (not shown), and the photoresist is patterned. The layer can roughly define a pattern of recesses R, and then, by patterning the photoresist layer as a patterned mask layer, performing an etching process such as reactive ion etching (reactive-ion-etching, RIE) The process removes a portion of the nitrogen ruthenium layer 14, a portion of the ruthenium oxide layer 12, and a portion of the substrate 10 to form trenches R in the substrate 10, and subsequently, removes the patterned photoresist layer. In addition, the pattern of the patterned photoresist layer may be transferred to the opening of the exposed portion of the substrate 10 by the nitrogen layer 14 and the silicon oxide layer 12, and then the patterned photoresist layer is removed. The nitride layer 14 and the germanium oxide layer 12 are collectively used as a patterned mask layer, and an etching process is performed to remove a portion of the substrate 10 to form the trench R. The manner of defining the patterned mask layer of the trench R pattern and forming the trench R is not limited thereto. Further, after the trench R is formed in the substrate 10, the patterned mask layer may be selectively performed. The process is pulled back to adjust the shape of the patterned mask layer.
接下來,形成一襯層16覆蓋基底10,特別是覆蓋於溝槽R的表面以修復形成溝槽R時對基底10表面造成的損傷。襯層16可為一氮化矽層、一氧化矽層或一氮氧化矽層組成的單層結構,或一氧化矽層與一氮化矽層組成的雙層結構。例如可利用熱氧化或化學氣相沈積(CVD)等製程形成氧化矽層再選擇性地對其進行氮化處理。在本實施例中,襯層16可係經由原處蒸汽產生(in situ steam generation,ISSG)製程形成的氧化矽層,但不以此為限。 Next, a liner 16 is formed to cover the substrate 10, particularly the surface of the trench R to repair damage to the surface of the substrate 10 when the trench R is formed. The lining layer 16 may be a single layer structure composed of a tantalum nitride layer, a ruthenium oxide layer or a ruthenium oxynitride layer, or a two-layer structure composed of a tantalum oxide layer and a tantalum nitride layer. For example, a ruthenium oxide layer can be formed by a process such as thermal oxidation or chemical vapor deposition (CVD) and then selectively nitrided. In this embodiment, the lining layer 16 may be a ruthenium oxide layer formed by an in situ steam generation (ISSG) process, but is not limited thereto.
隨後,如第3圖所示,形成一介電層18填入溝槽R。為使介電層18能夠完整填滿具高深寬比的溝槽R且防止孔洞的形成,較佳係進行一流動式化學氣相沈積(flowable chemical vapor deposition,FCVD)製程,包括下列步驟。首先,進行一沈積製程,形成一可流動介電材料層(圖未示)於基底10上。可流動介電材料層一般呈液態以完整覆蓋溝槽R的底部並充分填滿溝槽R,其材料包含三甲矽烷基氨(trisilylamine,TSA),但不以此為限。接著,對可流動介電材料層進行一固化(curing)製程,該固化製程可包括進行一臭氧(ozone,O3)電漿處理製程,以將可流動介電材料層轉化成介電層18例如氧化矽 層。固化製程之製程溫度範圍實質上係介於攝氏100度(℃)至250℃之間。固化製程較佳係在沈積製程後一次進行,以節省製程時間,但不限於此,固化製程也可與沈積製程交替進行。在其他實施例中,使可流動介電材料層轉化成介電層18的方法,也可藉由進行一氧化製程,包含直接通入氧氣、臭氧或水蒸氣等。 Subsequently, as shown in FIG. 3, a dielectric layer 18 is formed to fill the trenches R. In order to enable the dielectric layer 18 to completely fill the trench R having a high aspect ratio and prevent the formation of voids, it is preferred to perform a flowable chemical vapor deposition (FCVD) process, including the following steps. First, a deposition process is performed to form a layer of flowable dielectric material (not shown) on the substrate 10. The flowable dielectric material layer is generally in a liquid state to completely cover the bottom of the trench R and sufficiently fill the trench R, the material of which comprises, but is not limited to, trisilylamine (TSA). Next, a curting process is performed on the flowable dielectric material layer, and the curing process can include performing an ozone (O 3 ) plasma processing process to convert the flowable dielectric material layer into the dielectric layer 18 For example, a layer of cerium oxide The process temperature range of the curing process is substantially between 100 degrees Celsius (°C) and 250°C. The curing process is preferably performed once after the deposition process to save process time, but is not limited thereto, and the curing process may be alternated with the deposition process. In other embodiments, the method of converting the flowable dielectric material layer into the dielectric layer 18 can also include direct oxidation of oxygen, ozone, or water vapor by performing an oxidation process.
其中,介電層18不限由FCVD製程形成,也可藉由高密度電漿化學氣相沈積(High Density Plasma CVD,HDPCVD)、次常壓化學氣相沈積(sub atmosphere CVD,SACVD)或旋塗式介電材料(Spin on dielectric,SOD)等製程,以形成介電層18填滿溝槽R。 The dielectric layer 18 is not limited to being formed by an FCVD process, and may also be subjected to high-density plasma chemical vapor deposition (HDPCVD), sub-atmospheric chemical vapor deposition (SACVD) or spin. A process such as a spin-on dielectric (SOD) is used to form a dielectric layer 18 to fill the trenches R.
此外,為進一步加強介電層18的密度,在上述固化製程後,可再對介電層18進行一熱處理製程P1。熱處理製程P1包含一水蒸氣熱處理製程以及一氮氣熱處理製程,其中水蒸氣熱處理製程的一製程溫度範圍實質上介於600℃與800℃之間,而氮氣熱處理製程的一製程溫度實質上大於1000℃。更詳細地說,水蒸氣熱處理製程係通入水蒸氣(steam)於溫度範圍實質上介於600℃與800℃之間的反應腔室中;而氮氣熱處理製程係通入氮氣(nitrogen)於溫度實質上大於1000℃的反應腔室中。 In addition, in order to further strengthen the density of the dielectric layer 18, a heat treatment process P1 may be performed on the dielectric layer 18 after the above curing process. The heat treatment process P1 comprises a steam heat treatment process and a nitrogen heat treatment process, wherein a process temperature range of the steam heat treatment process is substantially between 600 ° C and 800 ° C, and a process temperature of the nitrogen heat treatment process is substantially greater than 1000 ° C . In more detail, the steam heat treatment process is steamed into a reaction chamber having a temperature range substantially between 600 ° C and 800 ° C; and the nitrogen heat treatment process is passed through a nitrogen atmosphere at a temperature substantial In a reaction chamber greater than 1000 ° C.
接下來,如第4圖所示,利用氮矽層14作為研磨停止層,對介電層18進行一化學機械研磨(chemical mechanical polishing,CMP)等之平坦化製程,去除部分介電層18與部分襯層16,以平坦化介電 層18形成介電層18’,且介電層18’之表面與氮矽層14之表面約略切齊。在化學機械研磨製程後,對介電層18’進行一表面處理製程P2,表面處理製程P2的製程溫度範圍較佳係小於上述熱處理製程P1的製程溫度範圍,且表面處理製程P2的製程時間亦較佳係小於上述熱處理製程P1的製程時間,以避免累積過多的熱預算(thermal budget)。在本實施例中,表面處理製程P2包含通入一氧(oxygen)電漿,例如一含氧的高密度電漿(high density plasma,HDP),製程溫度範圍實質上介於300℃與400℃之間,且製程時間實質上不超過1分鐘。 Next, as shown in FIG. 4, a planarization process such as chemical mechanical polishing (CMP) is performed on the dielectric layer 18 by using the yttrium nitride layer 14 as a polishing stop layer, and a portion of the dielectric layer 18 is removed. Part of the liner 16 to flatten the dielectric Layer 18 forms dielectric layer 18' and the surface of dielectric layer 18' is approximately flush with the surface of nitride layer 14. After the chemical mechanical polishing process, a surface treatment process P2 is performed on the dielectric layer 18', and the process temperature range of the surface treatment process P2 is preferably smaller than the process temperature range of the heat treatment process P1, and the process time of the surface treatment process P2 is also It is preferably less than the process time of the above heat treatment process P1 to avoid accumulating excessive thermal budget. In this embodiment, the surface treatment process P2 includes the introduction of an oxygen plasma, such as an oxygen-containing high density plasma (HDP), and the process temperature range is substantially between 300 ° C and 400 ° C. Between, and the process time is substantially no more than 1 minute.
值得注意的是,本實施例之表面處理製程P2係用於提供氧自由基(radical)以穿透入部分介電層18’,用以使介電層之表面的懸空鍵(dangling bond)彼此鍵結(crosslink),進而提高介電層18’之緻密度,其中氧自由基穿透的深度可藉由射頻(radio frequency,RF)功率(power)與製程時間進行調整。此時,介電層18’之上半部(被氧自由基穿透)的結構較介電層18’之下半部(未被氧自由基穿透)的結構較為緻密,因此,可避免後續進行的蝕刻及清洗製程中的蝕刻液或清洗劑破壞介電層18’之暴露的表面,甚或造成介電層18’兩側的基底10之損失,而有助於維持介電層18’的結構完整性及絕緣效果。另外,表面處理製程P2並不限於氧(oxygen)電漿,氧自由基也可藉由加熱或紫外線照射等方法解離含氧的氣體例如:氧氣(O2)或臭氧(O3)而得。 It should be noted that the surface treatment process P2 of the present embodiment is for providing oxygen radicals to penetrate into the partial dielectric layer 18' for dangling bonds of the surface of the dielectric layer. The junction further increases the density of the dielectric layer 18', wherein the depth of oxygen radical penetration can be adjusted by radio frequency (RF) power and process time. At this time, the structure of the upper half of the dielectric layer 18' (penetrated by oxygen radicals) is denser than the structure of the lower half of the dielectric layer 18' (not penetrated by oxygen radicals), and thus can be avoided. The etchant or cleaning agent in the subsequent etching and cleaning process destroys the exposed surface of the dielectric layer 18', or even causes loss of the substrate 10 on both sides of the dielectric layer 18', thereby helping to maintain the dielectric layer 18'. Structural integrity and insulation effects. Further, the surface treatment process P2 is not limited to an oxygen plasma, and oxygen radicals may be obtained by dissolving an oxygen-containing gas such as oxygen (O 2 ) or ozone (O 3 ) by heating or ultraviolet irradiation.
隨後,如第5圖所示,基於製程需求,在表面處理製程P2後,可選擇性再對介電層18’進行上述熱處理製程P1,也就是說,可以相同條件的熱處理製程P1來再次進行水蒸氣熱處理製程以及氮氣熱處理製程以進一步提高介電層18’的緻密度,其中熱處理製程P1的製程溫度範圍均係實質上大於表面處理製程P2的製程溫度範圍,當然,此處的熱處理製程亦可不同於之前熱處理製程P1的參數條件。然後,選擇性地進行一乾式或濕式蝕刻製程去除部分的介電層18’,調整介電層18’的上表面高度;在本發明的另一實施例中,可在化學機械研磨後但表面處理製程P2前對介電層18’選擇性地進行用以調整表面高度的蝕刻製程。最後,如第6圖所示,進行一剝除步驟,可包含例如:使用熱磷酸溶液去除剩餘的氮矽層14以及稀釋氫氟酸溶液去除剩餘的矽氧層12或突出於基底表面的介電層18’,或是進行一乾蝕刻製程,以去除剩餘的氮矽層14以及剩餘的矽氧層12。至此,完成淺溝渠隔離20。 Subsequently, as shown in FIG. 5, after the surface treatment process P2, the above-mentioned heat treatment process P1 may be selectively performed on the dielectric layer 18' based on the process requirements, that is, the heat treatment process P1 of the same condition may be used again. The steam heat treatment process and the nitrogen heat treatment process further increase the density of the dielectric layer 18', wherein the process temperature range of the heat treatment process P1 is substantially greater than the process temperature range of the surface treatment process P2, of course, the heat treatment process here is also It may be different from the parameter conditions of the previous heat treatment process P1. Then, a dry or wet etching process is selectively performed to remove portions of the dielectric layer 18' to adjust the upper surface height of the dielectric layer 18'; in another embodiment of the invention, after chemical mechanical polishing, An etching process for adjusting the surface height is selectively performed on the dielectric layer 18' before the surface treatment process P2. Finally, as shown in FIG. 6, performing a stripping step may include, for example, removing the remaining nitrogen ruthenium layer 14 using a hot phosphoric acid solution and diluting the hydrofluoric acid solution to remove the remaining ruthenium oxide layer 12 or protruding from the surface of the substrate. The electrical layer 18' is either subjected to a dry etching process to remove the remaining layer of nitrogen nitride 14 and the remaining layer of germanium oxide 12. At this point, the shallow trench isolation 20 is completed.
更詳細地說,當淺溝渠隔離20的介電層18’之表面已接觸過氧電漿,亦即介電層18’之表面已被氧電漿處理,將使部分介電層18’的緻密度有所增加,也就是說,介電層18’之表面的被蝕刻速率將可降低,因此,在進行上述的剝除步驟時,可有效避免介電層18’被過度移除至無法完整填滿溝槽R的程度例如:介電層18’的頂表面T1低於基底10的頂表面T2,據此,本發明的表面處理製程P2係有助於維持淺溝渠隔離20以及淺溝渠隔離20兩側的基底10之結構完整,特別是鄰近淺溝渠隔離20之頂面彎角的基底10之結構完 整。 In more detail, when the surface of the dielectric layer 18' of the shallow trench isolation 20 has been exposed to the oxygen plasma, that is, the surface of the dielectric layer 18' has been treated with oxygen plasma, a portion of the dielectric layer 18' will be The density is increased, that is, the etch rate of the surface of the dielectric layer 18' can be reduced. Therefore, when the stripping step described above is performed, the dielectric layer 18' can be effectively prevented from being excessively removed. The extent to which the trench R is completely filled, for example, is that the top surface T1 of the dielectric layer 18' is lower than the top surface T2 of the substrate 10, whereby the surface treatment process P2 of the present invention helps maintain shallow trench isolation 20 and shallow trenches. The structure of the substrate 10 on both sides of the isolation 20 is complete, in particular, the structure of the substrate 10 adjacent to the top corner of the shallow trench isolation 20 is completed. whole.
本發明也適用於非平面電晶體之淺溝渠隔離的介電層製程,請參考第7圖至第8圖。第7圖至第8圖繪示了本發明之另一較佳實施例之製作淺溝渠隔離的方法的示意圖。如第7圖所示,首先於基底10上形成一圖案化硬遮罩22,用以定義至少一鰭狀結構24。隨後進行一蝕刻製程,用以移除部份的基底10,而同時形成複數個鰭狀結構24以及其間之複數個溝槽R於基底10中。然後以上述的流動式化學氣相沈積(flowable chemical vapor deposition,FCVD)製程、高密度電漿化學氣相沈積(High Density Plasma CVD,HDPCVD)製程、次常壓化學氣相沈積(sub atmosphere CVD,SACVD)製程或旋塗式介電材料(Spin on dielectric,SOD)製程等於基底10上形成至少一介電材料層(圖未示),覆蓋該等鰭狀結構24並填滿溝槽R。之後再以化學機械研磨製程(CMP)來平坦化介電材料層以形成介電層26,且在化學機械研磨製程(CMP)後,對介電層26進行一表面處理製程P2,其中表面處理製程P2包括通入一氧(oxygen)電漿。最後,如第8圖所示,利用至少一蝕刻製程去除圖案化硬遮罩22以及部份介電層26,以於各鰭狀結構24間的基底10中形成相對應之淺溝渠隔離28。 The invention is also applicable to the dielectric layer process of shallow trench isolation of non-planar transistors, please refer to Figures 7 to 8. 7 to 8 are schematic views showing a method of fabricating shallow trench isolation according to another preferred embodiment of the present invention. As shown in FIG. 7, a patterned hard mask 22 is first formed on the substrate 10 to define at least one fin structure 24. An etching process is then performed to remove portions of the substrate 10 while forming a plurality of fin structures 24 and a plurality of trenches R therebetween in the substrate 10. Then, according to the above-described flowable chemical vapor deposition (FCVD) process, high-density plasma chemical vapor deposition (HDPCVD) process, sub-atmospheric chemical vapor deposition (sub-atmosphere CVD). The SACVD process or spin-on dielectric (SOD) process is equivalent to forming at least one dielectric material layer (not shown) on the substrate 10, covering the fin structures 24 and filling the trenches R. The dielectric material layer is then planarized by a chemical mechanical polishing process (CMP) to form the dielectric layer 26, and after the chemical mechanical polishing process (CMP), the dielectric layer 26 is subjected to a surface treatment process P2, wherein the surface treatment Process P2 includes the introduction of an oxygen plasma. Finally, as shown in FIG. 8, the patterned hard mask 22 and a portion of the dielectric layer 26 are removed by at least one etching process to form corresponding shallow trench isolations 28 in the substrate 10 between the fin structures 24.
本發明的特徵,例如前述之第1圖至第6圖以及第7圖至第8圖的實施例,在於對進行平坦化製程例如:化學機械研磨製程後的介電層,再進行一表面處理製程例如氧電漿處理製程,其中,介電 層可作為任一半導體裝置的元件隔離結構。而且,本發明除了適用於前述之平面電晶體或非平面電晶體之淺溝渠隔離的介電層製程,也可適用於其他元件隔離結構製程例如:層間介電層(inter-layer dielectric layer,ILD)製程或金屬層間介電層(inter-metal dielectric layer,IMD)製程。 Features of the present invention, such as the first to sixth and seventh to eighth embodiments described above, are those in which a planarization process such as a chemical mechanical polishing process is followed by a surface treatment. Process such as an oxygen plasma processing process in which a dielectric The layer can serve as an element isolation structure for any semiconductor device. Moreover, the present invention is applicable to other element isolation structure processes, such as an inter-layer dielectric layer (ILD), in addition to the dielectric layer process of the shallow trench isolation described above for a planar transistor or a non-planar transistor. Process or inter-metal dielectric layer (IMD) process.
以層間介電層為例,請參考第9圖與第10圖。第9圖至第10圖繪示了本發明之一較佳實施例之製作金屬內連線結構的方法的示意圖。如第9圖所示,首先提供一基板10,接著於其上形成平面或非平面元件,例如形成一閘極結構30於源極汲極摻雜區31之間的基板10上,閘極結構30包括閘極介電層32、閘極導電層34、蓋層(圖未示)以及側壁子38,其中閘極結構30之製程與材料為本領域之通常知識者所熟知,故不再贅述。當閘極導電層34係由多晶矽組成,可去除蓋層後,再進行一自對準金屬矽化物製程,以形成金屬矽化物層36於閘極導電層34以及源極汲極摻雜區31上。接著,依序進行一化學氣相沈積製程形成一接觸窗蝕刻停止層(contact etching stop layer,CESL)40以及形成一介電層42於基板10上,其中介電層42可包含低介電常數(dielectric constant,k)材料(介電常數值小於3.9)、超低介電常數(ultra low-k,以下簡稱為ULK)材料(介電常數值小於2.6)、或多孔性超低介電常數(porous ULK)材料,而形成介電層42的方法包含進行一FCVD、電漿加強化學氣相沉積(plasma enhanced chemical vapor deposition,PECVD)、常壓化學氣相沉積(atmospheric pressure chemical vapor deposition,APCVD)或次常 壓化學氣相沉積(sub-atmospheric pressure chemical vapor deposition,SACVD)之製程。 Take the interlayer dielectric layer as an example. Please refer to Figure 9 and Figure 10. 9 to 10 are schematic views showing a method of fabricating a metal interconnect structure according to a preferred embodiment of the present invention. As shown in FIG. 9, a substrate 10 is first provided, and then planar or non-planar elements are formed thereon, for example, a gate structure 30 is formed on the substrate 10 between the source drain doping regions 31, and the gate structure is formed. 30 includes a gate dielectric layer 32, a gate conductive layer 34, a cap layer (not shown), and a sidewall spacer 38. The process and materials of the gate structure 30 are well known to those of ordinary skill in the art, and thus will not be described again. . When the gate conductive layer 34 is composed of polysilicon, after the cap layer is removed, a self-aligned metal telluride process is performed to form the metal telluride layer 36 in the gate conductive layer 34 and the source drain doping region 31. on. Then, a chemical vapor deposition process is sequentially performed to form a contact etching stop layer (CESL) 40 and a dielectric layer 42 is formed on the substrate 10. The dielectric layer 42 may include a low dielectric constant. (dielectric constant, k) material (dielectric constant value less than 3.9), ultra low dielectric constant (ultra low-k, hereinafter referred to as ULK) material (dielectric constant value less than 2.6), or porous ultra low dielectric constant (porous ULK) material, and the method of forming the dielectric layer 42 includes performing an FCVD, a plasma enhanced chemical vapor deposition (PECVD), an atmospheric pressure chemical vapor deposition (APCVD). ) or less often Process of sub-atmospheric pressure chemical vapor deposition (SACVD).
接下來,對介電層42進行一化學機械研磨製程等之平坦化製程,且在化學機械研磨製程後,對平坦化的介電層42再進行一表面處理製程P2,其中表面處理製程P2包括通入一氧電漿,使介電層42內的懸空鍵因氧自由基的進入而彼此鏈結,相類似的,介電層42之上半部(被氧自由基穿透)的結構將較介電層42之下半部(未被氧自由基穿透)的結構較為緻密,因此可增加介電層42之表面的緻密度,避免後續進行的蝕刻及清洗製程中的蝕刻液或清洗劑破壞介電層42之表面,甚或造成介電層42的損失,以俾於維持介電層42的結構完整及絕緣效果。 Next, the dielectric layer 42 is subjected to a planarization process such as a chemical mechanical polishing process, and after the chemical mechanical polishing process, the planarized dielectric layer 42 is further subjected to a surface treatment process P2, wherein the surface treatment process P2 includes An oxygen plasma is introduced to cause the dangling bonds in the dielectric layer 42 to be linked to each other due to the entry of oxygen radicals. Similarly, the structure of the upper half of the dielectric layer 42 (penetrated by oxygen radicals) will The structure of the lower half of the dielectric layer 42 (not penetrated by oxygen radicals) is denser, so that the density of the surface of the dielectric layer 42 can be increased, and etching or cleaning in the subsequent etching and cleaning processes can be avoided. The agent destroys the surface of the dielectric layer 42 or even causes loss of the dielectric layer 42 to maintain the structural integrity and insulating effect of the dielectric layer 42.
隨後,如第10圖所示,於平坦化的介電層42上方,全面性形成一覆蓋層44,覆蓋層44包含介電材料。在其他實施例中,也可在介電層與覆蓋層的連續沈積製程後,對介電材料組成的覆蓋層施以平坦化製程以及表面處理製程P2,來使覆蓋層內的懸空鍵彼此鏈結,進而讓覆蓋層之上半部(被氧自由基穿透)的結構較覆蓋層之下半部(未被氧自由基穿透)的結構較為緻密。接著,再進行微影及蝕刻等製程,去除部分覆蓋層44、部分介電層42以及部分接觸窗蝕刻停止層40以形成至少一接觸窗開口O於介電層42中,且金屬矽化物層36將暴露於接觸窗開口O的底部,接下來,於接觸窗開口O內進一步依序形成一阻障層(圖未示)、一晶種層(圖未示)與一 填滿接觸窗開口O的導電層48,最後藉由一平坦化步驟使導電層48的表面與覆蓋層44的表面切齊,至此,完成金屬內連線結構的製作。在此由於上述金屬內連線製程係為熟習該項技藝之人士所熟知者,因此在本實施例中不再贅述。 Subsequently, as shown in FIG. 10, over the planarized dielectric layer 42, a cap layer 44 is formed in its entirety, the cap layer 44 comprising a dielectric material. In other embodiments, after the continuous deposition process of the dielectric layer and the cap layer, a planarization process and a surface treatment process P2 are applied to the cap layer composed of the dielectric material to make the dangling bonds in the cap layer interlock with each other. The structure, in turn, allows the structure of the upper half of the cover layer (penetrated by oxygen radicals) to be denser than the structure of the lower half of the cover layer (not penetrated by oxygen radicals). Then, a process such as lithography and etching is performed to remove a portion of the cap layer 44, a portion of the dielectric layer 42 and a portion of the contact etch stop layer 40 to form at least one contact opening O in the dielectric layer 42 and the metal telluride layer. 36 will be exposed to the bottom of the contact window opening O, and then, a barrier layer (not shown), a seed layer (not shown) and a layer are further sequentially formed in the contact window opening O. The conductive layer 48 of the contact window opening O is filled, and finally the surface of the conductive layer 48 is aligned with the surface of the cover layer 44 by a planarization step, and thus the fabrication of the metal interconnect structure is completed. The above-described metal interconnecting process is well known to those skilled in the art and will not be described in detail in this embodiment.
此外,本發明也可進一步應用於各種具有高介電常數介電層的半導體製程,例如金屬閘極製程包括先閘極(gate first)製程、後閘極(gate last)製程之先閘極介電層(high-k first)製程以及後閘極製程之後閘極介電層(high-k last)製程等。 In addition, the present invention can be further applied to various semiconductor processes having a high-k dielectric layer, for example, a gate-gate process including a gate first process and a gate last process. The high-k first process and the high-k last process after the gate process.
以後閘極製程之後閘極介電層製程為例,請參考第11圖至第13圖,並請一併參考第9圖。第11圖至第13圖繪示了本發明之一較佳實施例之製作金屬閘極結構的方法的示意圖。如第11圖所示。首先,提供一基底10,且基底10上設置有一介電層50覆蓋一虛置閘極結構如第9圖所示的閘極結構30,接著,進行一平坦化製程例如一化學機械研磨製程用以移除部分介電層50與蓋層至暴露出閘極導電層34,同樣地,為改善介電層50的結構強度,在化學機械研磨製程後將再對介電層50進行一表面處理製程P2例如氧電漿處理製程,以使介電層50之上半部(被氧自由基穿透)的結構較介電層50之下半部(未被氧自由基穿透)的結構較為緻密。然後,如第12圖所示,去除閘極導電層34及選擇性地去除閘極介電層32以形成一被側壁子38環繞的開口,並依序形成高介電常數介電層52、功函數金屬層54與金屬導電層56填入開口中,最後,進行另一平坦化製 程使剩餘的高介電常數介電層52之表面、功函數金屬層54之表面與金屬導電層56之表面均與介電層50之表面切齊,以完成金屬閘極結構58。在此由於金屬閘極結構之材料與製程係為熟習該項技藝之人士所熟知者,因此在本實施例中不再贅述。 For example, after the gate process, the gate dielectric layer process is taken as an example. Please refer to Figure 11 to Figure 13, and please refer to Figure 9 together. 11 to 13 are schematic views showing a method of fabricating a metal gate structure according to a preferred embodiment of the present invention. As shown in Figure 11. First, a substrate 10 is provided, and a dielectric layer 50 is disposed on the substrate 10 to cover a dummy gate structure such as the gate structure 30 shown in FIG. 9. Then, a planarization process such as a chemical mechanical polishing process is performed. To remove a portion of the dielectric layer 50 and the cap layer to expose the gate conductive layer 34, similarly, to improve the structural strength of the dielectric layer 50, the dielectric layer 50 is subjected to a surface treatment after the chemical mechanical polishing process. The process P2 is, for example, an oxygen plasma treatment process such that the structure of the upper half of the dielectric layer 50 (penetrated by oxygen radicals) is smaller than the structure of the lower half of the dielectric layer 50 (not penetrated by oxygen radicals). Dense. Then, as shown in FIG. 12, the gate conductive layer 34 is removed and the gate dielectric layer 32 is selectively removed to form an opening surrounded by the sidewalls 38, and a high-k dielectric layer 52 is sequentially formed. The work function metal layer 54 and the metal conductive layer 56 are filled in the opening, and finally, another planarization system is performed. The surface of the remaining high-k dielectric layer 52, the surface of the work function metal layer 54 and the surface of the metal conductive layer 56 are both aligned with the surface of the dielectric layer 50 to complete the metal gate structure 58. The materials and processes of the metal gate structure are well known to those skilled in the art and will not be described in detail in this embodiment.
隨後,如第13圖所示,於平坦化的介電層50上方,全面性形成一覆蓋層60,覆蓋層60包含介電材料。在其他實施例中,也可依序對介電材料組成的覆蓋層施以平坦化製程以及表面處理製程P2,使覆蓋層之上半部(被氧自由基穿透)的結構較覆蓋層之下半部(未被氧自由基穿透)的結構較為緻密。之後,再進行微影及蝕刻等製程,去除部分覆蓋層60以及部分介電層50以形成至少一接觸窗開口O’於覆蓋層60以及介電層50中。接著,進行一自對準金屬矽化物製程形成金屬矽化物層62於接觸窗開口O’的底部。接下來,如前述實施例,於接觸窗開口O’內進一步依序形成一阻障層(圖未示)、一晶種層(圖未示)與一填滿接觸窗開口O’的導電層64,最後藉由一平坦化步驟使導電層64的表面與覆蓋層60的表面切齊,至此,完成金屬內連線結構的製作。在此由於上述金屬內連線製程係為熟習該項技藝之人士所熟知者,因此在本實施例中不再贅述。 Subsequently, as shown in FIG. 13, a capping layer 60 is formed over the planarized dielectric layer 50, and the capping layer 60 comprises a dielectric material. In other embodiments, the planarization process and the surface treatment process P2 may be applied to the cover layer composed of the dielectric material in order, so that the upper half of the cover layer (penetrated by oxygen radicals) is more than the cover layer. The structure of the lower half (not penetrated by oxygen radicals) is denser. Thereafter, a process such as lithography and etching is performed to remove a portion of the cap layer 60 and a portion of the dielectric layer 50 to form at least one contact opening O' in the cap layer 60 and the dielectric layer 50. Next, a self-aligned metal telluride process is performed to form a metal telluride layer 62 at the bottom of the contact opening O'. Next, as in the foregoing embodiment, a barrier layer (not shown), a seed layer (not shown), and a conductive layer filling the contact opening O' are further sequentially formed in the contact opening O'. 64. Finally, the surface of the conductive layer 64 is aligned with the surface of the cover layer 60 by a planarization step, and thus the fabrication of the metal interconnect structure is completed. The above-described metal interconnecting process is well known to those skilled in the art and will not be described in detail in this embodiment.
綜上所述,本發明係使用流動式化學氣相沈積(flowable chemical vapor deposition,FCVD)製程形成介電層,使介電層可完整覆蓋基底且填滿溝槽,而不產生孔洞或空隙,達到良好溝槽填充(gap filling)效果。然後在完成介電層之平坦化製程後,對介電層之表面進行氧 電漿處理製程,可使氧自由基(radical)造成介電層內的懸空鍵(dangling bond)之鍵結(crosslink),以提高介電層之緻密度,尤其是提高提高介電層上半部之緻密度,使介電層之上半部(被氧自由基穿透)的結構較介電層之下半部(未被氧自由基穿透)的結構較為緻密,進而能有效避免介電層於後續的蝕刻及清洗製程中受到損傷,有助於維持介電層的結構完整性及絕緣效果。 In summary, the present invention uses a flowable chemical vapor deposition (FCVD) process to form a dielectric layer, so that the dielectric layer can completely cover the substrate and fill the trench without creating voids or voids. A good gap filling effect is achieved. Then, after completing the planarization process of the dielectric layer, oxygen is applied to the surface of the dielectric layer. The plasma treatment process can cause oxygen radicals to cause a dangling bond in the dielectric layer to increase the density of the dielectric layer, especially to improve the upper half of the dielectric layer. The density of the part makes the structure of the upper half of the dielectric layer (penetrated by oxygen radicals) denser than the lower part of the dielectric layer (not penetrated by oxygen radicals), thereby effectively avoiding The electrical layer is damaged during subsequent etching and cleaning processes to help maintain the structural integrity and insulation of the dielectric layer.
以上所述僅為本發明之較佳實施例,凡依本發明申請專利範圍所做之均等變化與修飾,皆應屬本發明之涵蓋範圍。 The above are only the preferred embodiments of the present invention, and all changes and modifications made to the scope of the present invention should be within the scope of the present invention.
10‧‧‧基底 10‧‧‧Base
12‧‧‧矽氧層 12‧‧‧Oxygen layer
14‧‧‧氮矽層 14‧‧‧Nitrate layer
16‧‧‧襯層 16‧‧‧ lining
18,18’,26,42,50‧‧‧介電層 18,18’,26,42,50‧‧‧ dielectric layer
20,28‧‧‧淺溝渠隔離 20,28‧‧‧Shallow trench isolation
22‧‧‧圖案化硬遮罩 22‧‧‧ patterned hard mask
24‧‧‧鰭狀結構 24‧‧‧Fin structure
30‧‧‧閘極結構 30‧‧‧ gate structure
31‧‧‧源極汲極摻雜區 31‧‧‧ source bungee doped area
32‧‧‧閘極介電層 32‧‧‧ gate dielectric layer
34‧‧‧閘極導電層 34‧‧‧ gate conductive layer
36,62‧‧‧金屬矽化物層 36,62‧‧‧metal telluride layer
38‧‧‧側壁子 38‧‧‧ Sidewall
40‧‧‧接觸窗蝕刻停止層 40‧‧‧Contact window etch stop layer
44,60‧‧‧覆蓋層 44, 60‧‧‧ cover
46‧‧‧金屬矽化物層 46‧‧‧metal telluride layer
48,64‧‧‧導電層 48,64‧‧‧ Conductive layer
52‧‧‧高介電常數介電層 52‧‧‧High dielectric constant dielectric layer
54‧‧‧功函數金屬層 54‧‧‧Work function metal layer
56‧‧‧金屬導電層 56‧‧‧Metal conductive layer
58‧‧‧金屬閘極結構 58‧‧‧Metal gate structure
R‧‧‧溝槽 R‧‧‧ trench
P1‧‧‧熱處理製程 P1‧‧‧ Heat treatment process
P2‧‧‧表面處理製程 P2‧‧‧ surface treatment process
T1,T2‧‧‧頂表面 T1, T2‧‧‧ top surface
O,O’‧‧‧接觸窗開口 O, O’‧‧‧Contact window opening
第1圖至第6圖繪示了本發明之一較佳實施例之製作淺溝渠隔離的方法的示意圖。 1 to 6 are schematic views showing a method of fabricating shallow trench isolation in accordance with a preferred embodiment of the present invention.
第7圖至第8圖繪示了本發明之另一較佳實施例之製作淺溝渠隔離的方法的示意圖。 7 to 8 are schematic views showing a method of fabricating shallow trench isolation according to another preferred embodiment of the present invention.
第9圖至第10圖繪示了本發明之一較佳實施例之製作金屬內連線結構的方法的示意圖。 9 to 10 are schematic views showing a method of fabricating a metal interconnect structure according to a preferred embodiment of the present invention.
第11圖至第13圖繪示了本發明之一較佳實施例之製作金屬閘極結構的方法的示意圖。 11 to 13 are schematic views showing a method of fabricating a metal gate structure according to a preferred embodiment of the present invention.
10‧‧‧基底 10‧‧‧Base
12‧‧‧矽氧層 12‧‧‧Oxygen layer
14‧‧‧氮矽層 14‧‧‧Nitrate layer
16‧‧‧襯層 16‧‧‧ lining
18’‧‧‧介電層 18'‧‧‧ dielectric layer
P2‧‧‧表面處理製程 P2‧‧‧ surface treatment process
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