TWI690059B - Semiconductor strucutre and method of fabricating the same - Google Patents
Semiconductor strucutre and method of fabricating the same Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims description 30
- 239000000758 substrate Substances 0.000 claims abstract description 68
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- 229910052814 silicon oxide Inorganic materials 0.000 description 9
- 229910052581 Si3N4 Inorganic materials 0.000 description 8
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- 238000005468 ion implantation Methods 0.000 description 3
- 150000002500 ions Chemical class 0.000 description 3
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Abstract
Description
本發明實施例是有關於一種半導體結構及其製造方法。 The embodiments of the present invention relate to a semiconductor structure and a manufacturing method thereof.
非揮發性記憶體(Non-Volatile Memory,NVM)單元陣列的製造已經整合於用於智慧卡(smart card)與汽車應用的先進的互補金屬氧化物半導體(CMOS)製程中。嵌入式NVM單元陣列的閘極高度通常高於周邊電路(periphery circuit)(例如邏輯元件)的閘極高度。在連續的化學機械研磨(chemical mechanical polishing,CMP)製程期間,嵌入式NVM單元陣列與邏輯元件之間的閘極高度差會導致凹陷問題(dishing issue)。 Non-Volatile Memory (NVM) cell array manufacturing has been integrated into advanced complementary metal oxide semiconductor (CMOS) manufacturing processes for smart card and automotive applications. The gate height of the embedded NVM cell array is usually higher than the gate height of peripheral circuits (such as logic elements). During the continuous chemical mechanical polishing (CMP) process, the gate height difference between the embedded NVM cell array and the logic device can cause a fishing issue.
根據本揭露的一些實施例,提供一種半導體結構,其包括半導體基底與至少一個圖案化的介電層。半導體基底包括半導體部分、至少一個第一元件、至少一個第二元件與至少一個第一虛設環。至少一個第一元件設置於被半導體部分環繞的第一區。至少一個第二元件與至少一個第一虛設環設置於第二區上,且第二區環繞第一區。至少一個圖案化的介電層覆蓋半導體基底。 According to some embodiments of the present disclosure, a semiconductor structure is provided, which includes a semiconductor substrate and at least one patterned dielectric layer. The semiconductor substrate includes a semiconductor portion, at least one first element, at least one second element, and at least one first dummy ring. At least one first element is disposed in the first region surrounded by the semiconductor portion. At least one second element and at least one first dummy ring are disposed on the second area, and the second area surrounds the first area. At least one patterned dielectric layer covers the semiconductor substrate.
根據本揭露的一些實施例,提供一種半導體結構,其包括半導體基底與至少一個圖案化的介電層。半導體基底包括主動區與環繞主動區的周邊區、設置於主動區上的至少一個第一元件、設置於周邊區上的至少一個第二元件以及設置於周邊區上的至少一個第一虛設環。至少一個第一元件與至少一個第二元件被主動區的半導體部分間隔開。至少一個圖案化的介電層設置於半導體基底上。至少一個第一元件、至少一個第二元件及至少一個第一虛設環嵌入於圖案化的介電層中。 According to some embodiments of the present disclosure, a semiconductor structure is provided, which includes a semiconductor substrate and at least one patterned dielectric layer. The semiconductor substrate includes an active region and a peripheral region surrounding the active region, at least one first component disposed on the active region, at least one second component disposed on the peripheral region, and at least one first dummy ring disposed on the peripheral region. At least one first element and at least one second element are spaced apart by the semiconductor portion of the active region. At least one patterned dielectric layer is disposed on the semiconductor substrate. At least one first element, at least one second element, and at least one first dummy ring are embedded in the patterned dielectric layer.
根據本揭露的一些實施例,提供一種半導體結構的製造方法,其包括以下步驟。提供具有半導體部分的半導體基底。在被半導體部分環繞的第一區上形成至少一個第一元件。在第二區上形成至少一個第二元件與至少一個第一虛設環,其中第二區環繞第一區,且至少一個第一虛設環環繞至少一個第一元件。在半導體基底上形成至少一個介電層,以覆蓋至少一個第一元件、至少一個第二元件以及至少一個第一虛設環。研磨至少一個介電層,直到至少一個第一元件、至少一個第二元件以及至少一個第一虛設環暴露出來。 According to some embodiments of the present disclosure, a method for manufacturing a semiconductor structure is provided, which includes the following steps. A semiconductor substrate having a semiconductor portion is provided. At least one first element is formed on the first region surrounded by the semiconductor portion. At least one second element and at least one first dummy ring are formed on the second area, wherein the second area surrounds the first area, and at least one first dummy ring surrounds at least one first element. At least one dielectric layer is formed on the semiconductor substrate to cover at least one first element, at least one second element, and at least one first dummy ring. Grind at least one dielectric layer until at least one first element, at least one second element, and at least one first dummy ring are exposed.
100:半導體基底 100: semiconductor substrate
100A:第一區 100A: District 1
100B:第二區
100B:
100B1:虛設區 100B1: dummy area
100B2:周邊電路區 100B2: Peripheral circuit area
102、102b:墊層 102, 102b: cushion
102a:濕氧化物層 102a: Wet oxide layer
104、106a、132a、132c、132d:圖案化的硬罩幕層 104, 106a, 132a, 132c, 132d: patterned hard mask curtain layer
106、132:硬罩幕層 106, 132: hard cover curtain layer
110a:第一溝渠隔離 110a: First trench isolation
110b:第二溝渠隔離 110b: Second trench isolation
112:半導體部分 112: Semiconductor part
120:硬罩幕頂蓋層 120: hard cover curtain top cover layer
120a:圖案化的硬罩幕頂蓋層 120a: Patterned hard cover curtain top layer
122:氧化物頂蓋層 122: oxide cap layer
122a:圖案化的氧化物頂蓋層 122a: Patterned oxide cap layer
124、124a、130、142:導電層 124, 124a, 130, 142: conductive layer
124b、142a:導電圖案 124b, 142a: conductive pattern
124c:浮置閘極電極 124c: floating gate electrode
126、128、136c、150:介電層 126, 128, 136c, 150: dielectric layer
126a、128b、150a1、150a2、150b1、150b2:介電圖案 126a, 128b, 150a1, 150a2, 150b1, 150b2: dielectric pattern
128a、128c:圖案化的介電層 128a, 128c: patterned dielectric layer
130a、130c:圖案化的導電層 130a, 130c: patterned conductive layer
130b:控制閘極電極 130b: control gate electrode
132b:硬罩幕圖案 132b: Hard cover curtain pattern
134a、134b、136a、136b、144、144a、172、176、178:間隙壁 134a, 134b, 136a, 136b, 144, 144a, 172, 176, 178: spacer
136d:氧化層 136d: oxide layer
138、146、168、PR:圖案化的光阻層 138, 146, 168, PR: patterned photoresist layer
140、170、174:摻雜區 140, 170, 174: doped regions
142b:選擇閘極電極 142b: Select gate electrode
148:圖案化的虛設層 148: Patterned dummy layer
148a、148a1、148b:虛設層 148a, 148a1, 148b: dummy layer
150a:第一部分 150a: part one
150b:第二部分 150b: Part Two
152:閘極電極 152: Gate electrode
154:介電頂蓋 154: Dielectric top cover
156、158、160、162、164、166:虛設圖案 156, 158, 160, 162, 164, 166: dummy patterns
180:停止層 180: stop layer
180a:圖案化的停止層 180a: patterned stop layer
182:層間介電層 182: Interlayer dielectric layer
182a:經研磨的層間介電層 182a: Grinded interlayer dielectric layer
200、200a:積體電路構件 200, 200a: Integrated circuit components
B:邊界區 B: border area
B1:邊界 B1: Border
B2:外邊界 B2: Outer boundary
D:距離 D: distance
DP:虛設點圖案 DP: Dummy dot pattern
DR1:第一虛設環 DR1: the first dummy ring
DR2:第二虛設環 DR2: second dummy ring
H1:第一高度 H1: first height
H2:第二高度 H2: second height
IS1、IS2、IS3:傾斜表面 IS1, IS2, IS3: inclined surface
M:記憶體單元陣列 M: memory cell array
MG:金屬閘極電極 MG: metal gate electrode
P:周邊電路 P: Peripheral circuit
R1、R2:凹槽 R1, R2: groove
TH1:第一厚度 TH1: first thickness
TH2:第二厚度 TH2: second thickness
X:部分 X: part
S1、S2:表面 S1, S2: surface
結合附圖閱讀以下詳細說明會最好地理解本揭露的各個方面。值得注意的是,根據業界的標準慣例,各種特徵並未按比例繪製。事實上,為了討論的清楚起見,各種特徵的尺寸可以任意增加或減小。 Reading the following detailed description in conjunction with the accompanying drawings will best understand the various aspects of the present disclosure. It is worth noting that, according to industry standard practices, various features are not drawn to scale. In fact, for clarity of discussion, the size of various features can be increased or decreased arbitrarily.
圖1至圖32是示意性地示出根據本揭露一些實施例的半導體 結構的製造方法的剖視圖。 1 to 32 are diagrams schematically showing semiconductors according to some embodiments of the present disclosure Cross-sectional view of a method of manufacturing a structure.
圖33是示意性地示出根據本揭露一些實施例的包括多個排列成陣列的積體電路構件的晶圓的上視圖。 33 is a top view schematically showing a wafer including a plurality of integrated circuit members arranged in an array according to some embodiments of the present disclosure.
圖34是示意性地示出根據本揭露一些實施例的圖33中所示的部分X的放大上視圖。 FIG. 34 is an enlarged top view schematically showing part X shown in FIG. 33 according to some embodiments of the present disclosure.
圖35是示意性地示出根據本揭露一些替代實施例的圖33中所示的部分X的放大上視圖。 FIG. 35 is an enlarged top view schematically showing part X shown in FIG. 33 according to some alternative embodiments of the present disclosure.
圖36A與圖36B是示意性地示出根據本揭露一些實施例的半導體結構的製造方法的剖視圖。 36A and 36B are cross-sectional views schematically showing a method of manufacturing a semiconductor structure according to some embodiments of the present disclosure.
圖37A至圖37C是示意性地示出根據本揭露一些替代實施例的半導體結構的製造方法的剖視圖。 37A to 37C are cross-sectional views schematically showing a method of manufacturing a semiconductor structure according to some alternative embodiments of the present disclosure.
以下揭露內容提供用於實現所提供主題的不同特徵的許多不同的實施例或實例。以下闡述元件及配置的具體實例以簡化本揭露內容。當然,這些僅為實例且不旨在進行限制。舉例來說,以下說明中將第一特徵形成於第二特徵“之上”或第二特徵“上”可包括其中第一特徵與第二特徵被形成為直接接觸的實施例,且也可包括其中第一特徵與第二特徵之間可形成有附加特徵,進而使得所述第一特徵與所述第二特徵可能不直接接觸的實施例。另外,本揭露內容可能在各種實例中重複使用參考編號及/或字母。這種重複是出於簡潔及清楚的目的,而不是自身表示所論述的各種實施例及/或配置之間的關係。 The following disclosure provides many different embodiments or examples for implementing different features of the provided subject matter. The following describes specific examples of components and configurations to simplify the disclosure. Of course, these are only examples and are not intended to be limiting. For example, forming the first feature "on" or "on" the second feature in the following description may include embodiments in which the first feature and the second feature are formed in direct contact, and may also include An embodiment in which additional features may be formed between the first feature and the second feature, so that the first feature and the second feature may not directly contact each other. In addition, the disclosure content may reuse reference numbers and/or letters in various examples. This repetition is for the purpose of brevity and clarity, rather than representing the relationship between the various embodiments and/or configurations discussed.
另外,為易於說明,本文中可能使用例如“在...之下(beneath)”、“在...下面(below)”、“下部的(lower)”、“在...上(on)”、“在...上方(above)”、“上部的(upper)”等空間相對性用語來闡述圖中所示的一個元件或特徵與另一(其他)元件或特徵的關係。所述空間相對性用語旨在除圖中所繪示的取向外還囊括裝置在使用或操作中的不同定向。設備可具有其他定向(旋轉90度或其他取向),且本文中所用的空間相對性用語可同樣相應地進行解釋。 In addition, for ease of explanation, for example, "beneath", "below", "lower", "on" may be used in this article )", "above", "upper" and other spatially relative terms to illustrate the relationship between one element or feature and another (other) element or feature shown in the figure. The term spatial relativity is intended to include different orientations of the device in use or operation in addition to the orientations depicted in the figures. The device may have other orientations (rotation 90 degrees or other orientations), and the terms of spatial relativity used herein may be interpreted accordingly accordingly.
圖1至圖32是示意性地示出了根據本揭露一些實施例的半導體結構的製造方法的剖視圖。 1 to 32 are cross-sectional views schematically showing a method of manufacturing a semiconductor structure according to some embodiments of the present disclosure.
參照圖1,提供半導體基底100。舉例來說,半導體基底100可為矽基底或由其他半導體材料製成的基底。在一些實施例中,如圖33所示,半導體基底100可為半導體晶圓(例如,矽晶圓或其類似物)。在半導體基底100上形成墊層(pad layer)102,並在墊層102上形成圖案化的硬罩幕層104。舉例來說,墊層102可以是氧化矽(SiOx,x>0)層,且圖案化的硬罩幕層104可以是氮化矽(SiNy,y>0)層。墊層102的材料與圖案化的硬罩幕層104的材料僅用於說明,且本揭露不限於此。如圖1所示,圖案化的硬罩幕層104可例如藉由微影與蝕刻製程形成,且部分墊層102被圖案化的硬罩幕層104暴露出來。在圖案化的硬罩幕層104的蝕刻製程中,墊層102可用作蝕刻停止層。
Referring to FIG. 1, a
參照圖1與圖2,進行濕式氧化製程,使得被墊層102覆蓋的部分半導體基底100被氧化,並在半導體基底100上形成濕氧化物(wet oxide layer)層102a。在進行濕式氧化製程之後,
形成了半導體基底100的凹槽R1,且在凹槽R1上形成了濕氧化物層102a。如圖1與圖2所示,濕氧化物層102a未被圖案化的硬罩幕層104覆蓋,且濕氧化物層102a比被圖案化的硬罩幕層104覆蓋的墊層102厚。舉例來說,濕氧化物層102a的厚度範圍為約100埃至約2000埃,且半導體基底100的凹槽R1的深度約為濕氧化物層102a的厚度的一半(例如,約50埃至約1000埃)。在一些實施例中,濕氧化物層102a的厚度可為約600埃,且半導體基底100的凹槽R1的深度可約為濕氧化物層102a的厚度的一半(例如,約300埃)。濕氧化物層102a的厚度與凹槽R1的深度僅用於說明,並且本揭露不限於此。
Referring to FIGS. 1 and 2, a wet oxidation process is performed so that a portion of the
參照圖2與圖3,藉由蝕刻製程部分地移除濕氧化物層102a,以在凹槽R1中形成另一墊層102b。凹槽R1中的墊層102b連接到被圖案化的硬罩幕層104覆蓋的墊層102。在一些實施例中,墊層102b與墊層102的厚度可大體上相同(例如,約10埃至約500埃)。在用於形成墊層102b的蝕刻製程期間,圖案化的硬罩幕層104可能被輕微蝕刻,且圖案化的硬罩幕層104的厚度損失可例如為約80埃。上述厚度損失及墊層102b與墊層102的厚度僅用於說明,且本揭露不限於此。
2 and 3, the
如圖2與圖3所示,半導體基底100可提供兩個表面S1與S2,其中表面S1與表面S2位於不同的水平高度,且表面S1與表面S2之間的水平高度差範圍例如為約50埃至約1000埃。上述表面S1與表面S2之間的水平高度差僅用於說明,且本揭露不限於此。
As shown in FIGS. 2 and 3, the
參照圖4,移除圖案化的硬罩幕層104,並在半導體基底100的表面S1上的墊層102上與半導體基底100的表面S2上的墊層102b上形成硬罩幕層106。舉例來說,硬罩幕層106可以是氮化矽層。硬罩幕層106的材料僅用於說明,且本揭露不限於此。
Referring to FIG. 4, the patterned
參照圖5,可對半導體基底100進行溝渠隔離製造製程,使得在半導體基底100中形成至少一個第一溝渠隔離110a(例如,至少一個內溝渠隔離)與至少一個第二溝渠隔離110b(例如,至少一個外溝渠隔離)。在形成至少一個第一溝渠隔離110a與至少一個第二溝渠隔離110b之後,定義半導體基底100的半導體部分112、第一區100A與第二區100B。在一些實施例中,第一區100A可為被至少一個第一溝渠隔離110a環繞的主動區,第二區100B可為周邊區。舉例來說,如圖34與圖35所示,第一區100A與第二區100B連接,第二區100B是環形周邊區,且第一區100A被環形第二區100B環繞。
Referring to FIG. 5, a trench isolation manufacturing process may be performed on the
在一些實施例中,上述溝渠隔離製造製程可包括:圖案化硬罩幕層106,以形成圖案化的硬罩幕層106a;例如藉由蝕刻製程在半導體基底100中形成多個溝渠;沉積介電材料以填充溝渠並覆蓋圖案化的硬罩幕層106a;以及對溝渠外的介電材料進行研磨(例如,CMP製程),直到圖案化的硬罩幕層106a暴露出來,如圖5所示。在一些實施例中,第一溝渠隔離110a與第二溝渠隔離110b例如是淺溝渠隔離(shallow trench isolation,STI)結構。然而,在本申請中,至少一個第一溝渠隔離110a與至少一個第二溝渠隔離110b的製造製程不受限制。
In some embodiments, the above trench isolation manufacturing process may include: patterning the
如圖5所示,半導體基底100的半導體部分112可以是環形結構,其與第一溝渠隔離110a及第二溝渠隔離110b接觸。第一溝渠隔離110a與第二溝渠隔離110b可位於半導體部分112的相對側。半導體部分112與第一溝渠隔離110a可位於第一區100A的邊界區B中。換句話說,邊界區B是半導體部分112與第一溝渠隔離110a所在的區域。舉例來說,半導體部分112靠近第一區100A與第二區100B之間的界面,而第二溝渠隔離110b靠近第一區100A與第二區100B之間的界面(圖5中所示的虛線)。此外,第一溝渠隔離110a的頂面、第二溝渠隔離110b的頂面以及圖案化的硬罩幕層106a的頂面大體上處於相同的水平。
As shown in FIG. 5, the
參照圖6,在第一溝渠隔離110a的頂面上、第二溝渠隔離110b的頂面上以及圖案化的硬罩幕層106a的頂面上形成頂蓋層。在一些實施例中,頂蓋層可包括硬罩幕頂蓋層120與形成在硬罩幕頂蓋層120上的氧化物頂蓋層122。硬罩幕頂蓋層120形成於第一溝渠隔離110a的頂面上、第二溝渠隔離110b的頂面上以及圖案化的硬罩幕層106a的頂面上。在一些實施例中,氧化物頂蓋層122的材料可與圖案化的硬罩幕層106a的材料不同,且氧化物頂蓋層122的材料可與墊層102的材料相同。舉例來說,硬罩幕頂蓋層120的材料可包括氮化矽,而氧化物頂蓋層122的材料可包括氧化矽。上述硬罩幕頂蓋層120與氧化物頂蓋層122的材料僅用於說明,且本揭露不限於此。
6, a top cover layer is formed on the top surface of the
參照圖7,例如藉由微影與蝕刻製程將硬罩幕頂蓋層120與氧化物頂蓋層122圖案化,以形成包括圖案化的硬罩幕頂蓋層120a與圖案化的氧化物頂蓋層122a的圖案化的頂蓋層。圖案化的
硬罩幕頂蓋層120a與圖案化的氧化物頂蓋層122a覆蓋第二溝渠隔離110b、位於第一溝渠隔離110a與第二溝渠隔離110b之間的圖案化的硬罩幕層106a以及靠近半導體部分112的部分第一溝渠隔離110a。
Referring to FIG. 7, for example, the hard mask
藉由利用圖案化的硬罩幕頂蓋層120a與圖案化的氧化物頂蓋層122a作為罩幕,例如藉由蝕刻製程移除位於墊層102b上的部分圖案化的硬罩幕層106a,直到墊層102b暴露出來。在一些實施例中,在用於部分移除圖案化的硬罩幕層106a的蝕刻製程期間,由於圖案化的氧化物頂蓋層122a(例如,氧化矽)的材料不同於圖案化的硬罩幕層106a的材料及圖案化的硬罩幕頂蓋層120a(例如,氮化矽)的材料,因此可選擇性地蝕刻圖案化的硬罩幕層106a。此外,在用於部分移除圖案化的硬罩幕層106a的蝕刻製程期間,由於圖案化的氧化物頂蓋層122a(例如,氧化矽)的材料與墊層102b的材料相同,因此墊層102b可用作蝕刻停止層。上述墊層102b的材料、圖案化的硬罩幕層106a的材料、圖案化的硬罩幕頂蓋層120a的材料以及圖案化的氧化物頂蓋層122a的材料僅用於說明,且本揭露不限於此。
By using the patterned hard mask
參照圖7與圖8,移除墊層102b,並在半導體基底100的表面S2上形成介電層126。在一些實施例中,介電層126可為氧化矽層。接著,在圖案化的氧化物頂蓋層122a、第一溝渠隔離110a及介電層126上形成導電層124。在一些實施例中,導電層124可為摻雜多晶矽層。舉例來說,導電層124可藉由沉積多晶矽層、將摻質植入多晶矽層以及對摻雜多晶矽層進行退火來形成。
上述導電層124的材料及介電層126的材料僅用於說明,且本揭露不限於此。
7 and 8, the
參照圖8與圖9,對導電層124進行研磨製程(例如,CMP製程),以形成具有平坦化頂面的導電層124a。導電層124a覆蓋介電層126與第一溝渠隔離110a。在導電層124的研磨製程期間,圖案化的氧化物頂蓋層122a被研磨,直到圖案化的硬罩幕頂蓋層120a暴露出來。圖案化的硬罩幕頂蓋層120a在導電層124的研磨製程期間可用作研磨停止層。如圖9所示,圖案化的硬罩幕頂蓋層120a的頂面與導電層124a的頂面大體上處於同一水平。
Referring to FIGS. 8 and 9, a polishing process (for example, a CMP process) is performed on the
參照圖9與圖10,例如藉由蝕刻製程進一步圖案化導電層124a,使得在介電層126上形成至少一個導電圖案124b。在導電層124a的蝕刻製程中,未被圖案化的硬罩幕頂蓋層120a覆蓋的部分第一溝渠隔離110a可被部分地移除。如圖10所示,舉例來說,於第一溝渠隔離110a中形成凹槽R2,且凹槽R2靠近導電圖案124b。
Referring to FIGS. 9 and 10, for example, the
參照圖10與圖11,依次形成介電層128、導電層130以及硬罩幕層132,以覆蓋導電圖案124b、第一溝渠隔離110a以及圖案化的硬罩幕頂蓋層120a。介電層128覆蓋導電圖案124b、第一溝渠隔離110a及圖案化的硬罩幕頂蓋層120a。導電層130覆蓋介電層128。硬罩幕層132覆蓋導電層130。在一些實施例中,介電層128可為氧化矽層。導電層130可為摻雜多晶矽層。舉例來說,導電層130可藉由沉積多晶矽層、將摻質植入多晶矽層以及對摻雜多晶矽層進行退火來形成。硬罩幕層132可為氧化矽/氮化矽/氧化矽堆疊層。然而,硬罩幕層132的配置不受限制。上述
介電層128的材料、導電層130的材料及硬罩幕層132的材料僅用於說明,且本揭露不限於此。
10 and 11, a
參照圖11與圖12,例如藉由微影與蝕刻製程將介電層128、導電層130及硬罩幕層132圖案化,使得形成圖案化的介電層128a、介電圖案128b、圖案化的導電層130a、控制閘極電極130b、圖案化的硬罩幕層132a以及硬罩幕圖案132b。圖案化的介電層128a、圖案化的導電層130a以及圖案化的硬罩幕層132a被形成為覆蓋第一溝渠隔離110a與圖案化的硬罩幕頂蓋層120a。介電圖案128b、控制閘極電極130b以及硬罩幕圖案132b被形成為部分地覆蓋導電圖案124b。在介電層128、導電層130及硬罩幕層132的圖案化製程期間,導電圖案124b可被輕微地過蝕刻(over-etch)。
Referring to FIGS. 11 and 12, for example, the
參照圖12與圖13,形成間隙壁134a與間隙壁134b。間隙壁134a形成於圖案化的介電層128a的側壁、圖案化的導電層130a的側壁及圖案化的硬罩幕層132a的側壁上。間隙壁134b形成於介電圖案128b的側壁、控制閘極電極130b的側壁以及硬罩幕圖案132b的側壁上。
12 and 13, a
在形成間隙壁134a與間隙壁134b之後,進行圖案化製程(例如,蝕刻製程),以移除未被間隙壁134a及間隙壁134b覆蓋的部分導電圖案124b及部分介電層126,使得在半導體基底100的表面S2上形成多個浮置閘極電極124c與多個介電圖案126a。浮置閘極電極124c及介電圖案126a與介電圖案128b、控制閘極電極130b及硬罩幕圖案132b自對準。由於導電圖案124b被輕微過蝕刻,因此每個間隙壁134b的底部部分可在導電圖案
124b上側向地延伸,且間隙壁134b的底部部分可與浮置閘極電極124c接觸。
After forming the
參照圖13與圖14,在形成浮置閘極電極124c與介電圖案126a之後,形成多個間隙壁136a與間隙壁136b。間隙壁136a形成於間隙壁134a上,而間隙壁136b形成於間隙壁134b上。此外,間隙壁136b覆蓋浮置閘極電極124c的側壁及介電圖案126a的側壁。接著,形成圖案化的光阻層138,並進行離子植入製程,使得在半導體基底100中形成多個摻雜區140(例如,共源極區)。在一些實施例中,可進一步進行退火製程,以退火半導體基底100中的摻雜區140,使得植入的離子或摻質可以擴散。
Referring to FIGS. 13 and 14, after forming the floating
參照圖14與圖15,在半導體基底100中形成摻雜區140之後,移除被圖案化的光阻層138的開口暴露的間隙壁136b,直到間隙壁134b、浮置閘極電極124c的側壁以及介電圖案126a的側壁被圖案化的光阻層138的開口暴露出來。接著,在圖案化的光阻層138的開口中形成多個介電層136c,以覆蓋間隙壁134b、浮置閘極電極124c的側壁及介電圖案126a的側壁,並形成多個氧化層136d(例如,共源極氧化層(common source oxidation layer,CSOX)),以覆蓋形成在半導體基底100中的摻雜區140。
14 and 15, after the doped
在一些實施例中,為了防止由圖案化的光阻層138導致的污染,在形成介電層136c與氧化層136d之前移除圖案化的光阻層138。在一些實施例中,圖案化的光阻層138可藉由例如灰化(ashing)製程或其他合適的製造來移除。
In some embodiments, to prevent contamination caused by the patterned
參照圖16與圖17,在半導體基底100上依次形成閘極介電層(未示出)與導電層142。在一些實施例中,導電層142
可為摻雜多晶矽層。舉例來說,導電層142可藉由沉積多晶矽層,將摻質植入多晶矽層,並對摻雜多晶矽層進行退火來形成。上述導電層142的材料僅用於說明,且本揭露不限於此。接著,對導電層142依次進行研磨製程(例如,CMP製程)與回蝕刻製程,使得形成多個具有平坦化頂面的導電圖案142a。在一些實施例中,可研磨導電層142直到暴露出圖案化的硬罩幕層132a,並可回蝕刻經研磨的導電層142,以形成導電圖案142a。
Referring to FIGS. 16 and 17, a gate dielectric layer (not shown) and a
參照圖17與圖18,在形成導電圖案142a之後,在導電圖案142a上形成多個間隙壁144,以覆蓋間隙壁136a、間隙壁136b與介電層136c。接著,例如藉由回蝕刻製程圖案化導電圖案142a與閘極介電層,以形成多個選擇閘極電極142b(例如,在摻雜區140及/或字元線上方的抹除閘極電極(erase gate electrode))以及位於選擇閘極電極142b下的多個選擇閘極氧化物層(select gate oxide layer,SGOX)。換句話說,未被多個間隙壁144覆蓋的導電圖案142a及閘極介電層被部分蝕刻,以形成多個選擇閘極電極142b。
Referring to FIGS. 17 and 18, after the
參照圖18與圖19,進行對間隙壁144與圖案化的硬罩幕層132a的研磨製程(例如,CMP製程),使得形成具有降低的高度的多個間隙壁144a與圖案化的硬罩幕層132c。在間隙壁144與圖案化的硬罩幕層132a的研磨製程期間,部分間隙壁134a、部分間隙壁134b、部分間隙壁136a、部分間隙壁136b以及部分介電層136c被研磨。在一些實施例中,在進行間隙壁144與圖案化的硬罩幕層132a的研磨製程之前,可塗佈用於研磨製程的底部層(未示出),以覆蓋研磨間隙壁144與圖案化的硬罩幕層132a之
前的半導體基底100上的結構。並且,可在間隙壁144與圖案化的硬罩幕層132a的研磨之後,移除底部層(未示出)。在進行間隙壁144與圖案化的硬罩幕層132a的研磨製程之後,可形成虛設層148a以覆蓋半導體基底100的第一區100A與第二區100B。在一些實施例中,虛設層148a可包括襯氧化物層及堆疊於襯氧化物層上的虛設多晶矽層。虛設層148a可藉由依次沉積襯氧化物層與多晶矽層,並回蝕刻多晶矽層,以在襯氧化物層上形成虛設多晶矽層而形成。虛設層148a的材料及配置僅用於說明,且本揭露不限於此。
Referring to FIGS. 18 and 19, a grinding process (for example, a CMP process) is performed on the
參照圖20與圖21,形成圖案化的光阻層146以覆蓋部分虛設層148a。接著,例如藉由微影與蝕刻製程將虛設層148a、圖案化的介電層128a、圖案化的導電層130a以及圖案化的硬罩幕層132c圖案化,使得在半導體基底100的第一區100A上形成虛設層148a1、圖案化的介電層128c、圖案化的導電層130c以及圖案化的硬罩幕層132d。在一些實施例中,圖案化的導電層130c與圖案化的硬罩幕層132d可為環形結構。在虛設層148a1、圖案化的介電層128c、圖案化的導電層130c以及圖案化的硬罩幕層132d形成之後,可藉由例如灰化製程或其他合適的製程來移除圖案化的光阻層146。在移除圖案化的光阻層146之後,可在半導體基底100的第一區100A及第二區100B上形成虛設層148b。在一些實施例中,虛設層148b可包括虛設多晶矽層。虛設層148b的材料與配置僅用於說明,且本揭露不限於此。
20 and 21, a patterned
參照圖21與圖22,在形成虛設層148b之後,部分地移除虛設層148a1與虛設層148b,直到圖案化的硬罩幕層106a、第
一溝渠隔離110a及第二溝渠隔離110b暴露出來,使得形成了圖案化的虛設層148。如圖22所示,移除未被圖案化的虛設層148覆蓋的圖案化的硬罩幕層106a及墊層102,直到暴露出半導體基底100的半導體部分112。
21 and 22, after forming the
參照圖22與圖23,在移除圖案化的硬罩幕層106a及墊層102之後,部分第一溝渠隔離110a及第二溝渠隔離110b被圖案化的虛設層148暴露出。所述部分第一溝渠隔離110a及第二溝渠隔離110b被部分地移除並平坦化,使得第一溝渠隔離110a的頂面、第二溝渠隔離110b的頂面及半導體部分112的頂面大體上位於同一水平。在一些實施例中,第一溝渠隔離110a及第二溝渠隔離110b的部分移除可藉由例如蝕刻製程來進行。
Referring to FIGS. 22 and 23, after removing the patterned
參照圖23與圖24,形成介電層150,以覆蓋圖案化的虛設層148、第一溝渠隔離110a、嵌入第二區100B的虛設區100B1中的第二溝渠隔離110b、半導體部分112以及第二區100B的周邊電路區100B2。虛設區100B1位於周邊電路區100B2與第一區100A之間。介電層150可包括第一部分150a與第二部分150b。第一部分150a不僅覆蓋圖案化的虛設層148、第一溝渠隔離110a及半導體部分112,而且還部分覆蓋第二溝渠隔離110b。第二部分150b不僅部分覆蓋第二溝渠隔離110b,而且還覆蓋虛設區100B1。如圖24所示,第二溝渠隔離110b的一部分(例如,左邊部分)被第一部分150a覆蓋,且第二溝渠隔離110b的另一部分(例如,右邊部分)被第二部分150b覆蓋。第一部分150a比第二部分150b厚,且厚度差的範圍例如是約10埃至約500埃。第
一部分150a與第二部分150b之間的厚度差僅用於說明,且本揭露不限於此。
23 and 24, a
如圖36A與圖36B所示,在一些實施例中,包括第一部分150a與第二部分150b的介電層150可由以下製程形成。首先,例如藉由沉積製程(例如,化學氣相沉積或其類似製程)形成介電材料層150M(如圖36A所示),以覆蓋圖23所示的所得結構,並藉由微影製程在介電材料層150M上形成圖案化的光阻層PR。舉例來說,介電材料層150M的材料包括氧化物、氮化物、氮氧化物、其組合或其類似物。藉由使用圖案化的光阻層PR作為罩幕,可藉由蝕刻製程或其他合適的圖案化製程來移除未被圖案化的光阻層PR覆蓋的部分介電材料層150M。在形成介電層150之後,移除圖案化的光阻層PR。如圖36B所示,第一區100A的邊界B1至第一部分150a的外邊界B2之間的距離D的範圍可為約0.1微米至約50微米。當第一區100A的邊界B1至第一部分150a的外邊界B2之間的距離D大於約0.1微米時,有足夠的空間用於形成第一虛設環DR1(如圖29至圖32所示),使得第一虛設環DR1(圖29至圖32所示)具有足夠的強度來阻止CMP凹陷(dishing)的擴展。
As shown in FIGS. 36A and 36B, in some embodiments, the
如圖37A與圖37B所示,在一些替代實施例中,包括第一部分150a與第二部分150b的介電層150可由如下製程形成。首先,例如藉由沉積製程(例如,化學氣相沉積或其類似製程)形成介電材料層150M(如圖36A所示),以覆蓋圖23所示的所得結構,並藉由微影製程在介電材料層150M上形成圖案化的光阻層PR。藉由使用圖案化的光阻層PR作為罩幕,可藉由蝕刻製程
或其他合適的圖案化製程來移除未被圖案化的光阻層PR覆蓋的介電材料層150M,使得第二溝渠隔離110b的一部分(例如,左邊部分)被第一部分150a覆蓋,且第二溝渠隔離110b的另一部分(例如,右邊部分)被暴露出來。在形成第一部分150a之後,可藉由選擇性生長製程僅在周邊電路區100B2上形成第二部分150b(即,第二部分150b不覆蓋第二溝渠隔離110b)。在形成第一部分150a之後或在形成第二部分150b之後,移除圖案化的光阻層PR。如圖37B與圖37C所示,第一區100A的邊界B1至第一部分150a的外邊界B2之間的距離D的範圍可為約0.1微米至約50微米。當第一區100A的邊界B1至第一部分150a的外邊界B2之間的距離D大於約0.1微米時,有足夠的空間用於形成第一虛設環DR1(如圖29至圖32所示),使得第一虛設環DR1(如圖29至圖32所示)可具有足夠的強度來阻止CMP凹陷的擴展。
As shown in FIGS. 37A and 37B, in some alternative embodiments, the
在一些實施例中,未使用圖37C所示的製程。換句話說,在一些實施例中,沒有使用在周邊電路區100B2上的第二部分150b的形成。
In some embodiments, the process shown in FIG. 37C is not used. In other words, in some embodiments, the formation of the
參照圖24與圖25,在形成介電層150之後,在周邊電路區100B2上形成多個閘極電極152(例如,多晶矽閘極電極)以及設置於多個閘極電極152上的多個介電頂蓋154。閘極電極152的材料僅用於說明,且本揭露不限於此。在一些實施例中,在形成閘極電極152與介電頂蓋154時,可形成多個虛設圖案156、虛設圖案158、虛設圖案160、虛設圖案162、虛設圖案164及虛設圖案166。虛設圖案156、虛設圖案160及虛設圖案164的材料可與閘極電極152的材料相同,而虛設圖案158、虛設圖案162
及虛設圖案166的材料可與介電頂蓋154的材料相同。虛設圖案156及設置於虛設圖案156上的虛設圖案158形成於第二部分150b上且位於虛設區100B1上方。虛設圖案160及設置於虛設圖案160上的虛設圖案162形成於第一部分150a上且位於虛設區100B1上方。虛設圖案164及設置於虛設圖案164上的虛設圖案166形成於第一部分150a上且位於第一區100A的上方。由於第一部分150a與第二部分150b之間的厚度差,虛設圖案162與虛設圖案166的頂面高於虛設圖案158的頂面與介電頂蓋154的頂面。舉例來說,虛設圖案156與虛設圖案158是點狀(dot-shaped)虛設圖案,而虛設圖案160、虛設圖案162、虛設圖案164及虛設圖案166是環形(ring-shaped)虛設圖案。點狀虛設圖案156與點狀虛設圖案158可隨機地(如圖34與圖35所示)或規律地分佈在第二溝渠隔離110b上方。
24 and 25, after the
在一些實施例中,可根據設計要求省略虛設圖案164與虛設圖案166的製造。在一些替代實施例中,可根據設計要求省略虛設圖案156與虛設圖案158的製造。在一些替代實施例中,可根據設計要求省略虛設圖案156、虛設圖案158、虛設圖案164及虛設圖案166的製造。
In some embodiments, the manufacture of the
參照圖25與圖26,在形成閘極電極152、介電頂蓋154以及虛設圖案156、虛設圖案158、虛設圖案160、虛設圖案162、虛設圖案164及虛設圖案166之後,可在介電層150上形成圖案化的光阻層168,使得閘極電極152、介電頂蓋154以及虛設圖案156、虛設圖案158、虛設圖案160、虛設圖案162、虛設圖案164及虛設圖案166被圖案化的光阻層168覆蓋。舉例來說,進行微
影與蝕刻製程,以圖案化介電層150並移除圖案化的虛設層148。然後,進行離子植入製程,使得在半導體基底100中形成多個摻雜區170(例如,輕摻雜汲極區)。在一些實施例中,可進一步進行退火製程以退火半導體基底100中的摻雜區170,使得所植入的離子或摻質可以擴散。
25 and 26, after forming the
在一些實施例中,在形成摻雜區170之前或之後,可在周邊電路區100B2中形成圖26中未示出的多個輕摻雜區(例如,輕摻雜汲極區)。
In some embodiments, before or after the doped
參照圖27,在形成摻雜區170之後,在選擇閘極電極142b的側壁上形成多個間隙壁172,並進行離子植入製程,以在半導體基底100中形成多個摻雜區174(例如,汲極區)。在一些實施例中,可進一步進行退火製程,以退火半導體基底100中的摻雜區174,使得所植入的離子或摻質可以擴散。在形成摻雜區174之後,形成記憶體單元陣列M(即,第一元件)。在一些實施例中,記憶體單元陣列M可包括排列成陣列的多個記憶單元。舉例來說,記憶體單元陣列M可以是非揮發性記憶體單元陣列,例如快閃記憶體單元陣列或其類似物。記憶體單元陣列M的類型僅用於說明,且本揭露不限於此。
Referring to FIG. 27, after the doped
如圖27所示,介電層150被圖案化,以形成多個介電圖案150a1、介電圖案150a2、介電圖案150b1及介電圖案150b2。介電圖案150a1設置於第一溝渠隔離110a與虛設圖案164之間,介電圖案150a2設置於第二溝渠隔離110b與虛設圖案160之間,介電圖案150b1設置於半導體基底100與閘極電極152之間,且介電圖案150b2設置於第二溝渠隔離110b與虛設圖案156之間。
舉例來說,介電圖案150a1、介電圖案150a2、介電圖案150b1及介電圖案150b2的材料可包括氧化物、氮化物、氮氧化物及其組合。
As shown in FIG. 27, the
在一些實施例中,在閘極電極152的側壁、介電頂蓋154的側壁及介電圖案150b1的側壁上形成多個間隙壁176,而在虛設圖案156、虛設圖案158、虛設圖案160、虛設圖案162、虛設圖案164及虛設圖案166的側壁以及介電圖案150a1、介電圖案150a2及介電圖案150b2的側壁上形成多個間隙壁178。此外,可在形成摻雜區174之前或之後,在周邊電路區100B2中形成圖27中未示出的多個摻雜區(例如,汲極區),使得在周邊電路區100B2上可形成周邊電路P(即,第二元件)。周邊電路P可包括多個邏輯元件(例如,MOS元件,每個MOS元件包括介電圖案150b1、閘極電極152及周邊電路區100B2中的摻雜區)。在一些實施例中,周邊電路P可包括核心元件(core device)、靜態隨機存取記憶體(static random access memory,SRAM)以及輸入/輸出元件。周邊電路P的類型僅用於說明,且本揭露不限於此。
In some embodiments, a plurality of
參照圖27與圖28,例如進行回蝕刻製程,以移除介電頂蓋154、虛設圖案158、虛設圖案162及虛設圖案166、間隙壁144a、硬罩幕圖案132b及圖案化的硬罩幕層132d。在上述回蝕刻製程期間,介電層136c與間隙壁134a、間隙壁134b、間隙壁136a、間隙壁136b、間隙壁172、間隙壁176及間隙壁178被部分地移除且其高度降低。在進行回蝕刻製程之後,圖案化的導電層130c、記憶體單元陣列M、第一虛設環DR1、第二虛設環DR2、多個虛設點圖案(dummy dot pattern)DP以及周邊電路P暴露出來。第
一虛設環DR1的頂面與第二虛設環DR2的頂面例如是大體上平坦的表面。第一虛設環DR1與第二虛設環DR2設置在記憶體單元陣列M與虛設點圖案DP之間。第二虛設環DR2設置在記憶體單元陣列M與第一虛設環DR1之間。由於第二虛設環DR2設置在記憶體單元陣列M與第一虛設環DR1之間,因此第二虛設環DR2是內虛設環,且第一虛設環DR1是外虛設環。
Referring to FIGS. 27 and 28, for example, an etch-back process is performed to remove the
在一些實施例中,第一虛設環DR1、第二虛設環DR2及虛設點圖案DP是電性浮置的,這是因為第一虛設環DR1與虛設點圖案DP形成於第二溝渠隔離110b上,且第二虛設環DR2形成於第一溝渠隔離110a上。換句話說,第一虛設環DR1、第二虛設環DR2及虛設點圖案DP彼此電絕緣。此外,第一虛設環DR1、第二虛設環DR2以及虛設點圖案DP與其他半導體元件(例如,記憶體單元陣列M及周邊電路P)電絕緣。
In some embodiments, the first dummy ring DR1, the second dummy ring DR2, and the dummy dot pattern DP are electrically floating, because the first dummy ring DR1 and the dummy dot pattern DP are formed on the
如圖28所示,在一些實施例中,圖案化的導電層130c可以是環形結構,且記憶體單元陣列M被圖案化的導電層130c環繞。第一虛設環DR1設置於虛設區100B1上,且第一虛設環DR1位於第二虛設環DR2與虛設點圖案DP之間。第一虛設環DR1可以是包括介電圖案150a2、虛設圖案160(例如多晶矽圖案)及間隙壁178的膜堆疊,其中虛設圖案160堆疊於介電圖案150a2上,且間隙壁178覆蓋介電圖案150a2的側壁及虛設圖案160的側壁。第二虛設環DR2可以是包括介電圖案150a1、虛設圖案164(例如多晶矽圖案)以及間隙壁178的膜堆疊,其中虛設圖案164堆疊於介電圖案150a1上,且間隙壁178覆蓋介電圖案150a1的側壁及虛設圖案164的側壁。每個虛設點圖案DP可以是包括介電
圖案150b2、虛設圖案156(例如多晶矽圖案)以及間隙壁178的膜堆疊,其中虛設圖案156堆疊於介電圖案150b2上,且間隙壁178覆蓋介電圖案150b2的側壁及虛設圖案156的側壁。舉例來說,介電圖案150a1、介電圖案150a2及介電圖案150b2的材料可包括氧化物,氮化物,氮氧化物及其組合。間隙壁178的材料可包括氧化物、氮化物、氮氧化物及其組合。介電圖案150a1、介電圖案150a2及介電圖案150b2的材料、虛設圖案156、虛設圖案160及虛設圖案164的材料以及間隙壁178的材料僅用於說明,且本揭露不限於此。
As shown in FIG. 28, in some embodiments, the patterned
如圖28、圖34及圖35所示,記憶體單元陣列M被圖案化的導電層130c環繞。記憶體單元陣列M與周邊電路P被第一溝渠隔離110a及第二溝渠隔離110b間隔開。第一虛設環DR1環繞記憶體單元陣列M。記憶體單元陣列M的第一高度H1(例如,第一閘極高度)大於周邊電路P的第二高度H2(例如,第二閘極高度)、第一虛設環DR1的第一厚度TH1以及第二虛設環DR2的第二厚度TH2。第一厚度TH1與第二厚度TH2大體上彼此相等且大於第二高度H2。換句話說,記憶體單元陣列M的頂面高於周邊電路P的頂面,且記憶體單元陣列M的頂面可略高於或大體上等於第一虛設環DR1的頂面及第二虛設環DR2的頂面。此外,由於介電圖案150a1與介電圖案150a2比介電圖案150b1與介電圖案150b2厚,因此第一虛設環DR1的頂面與第二虛設環DR2的頂面高於周邊電路P的頂面與虛設點圖案DP的頂面。在一些實施例中,第一虛設環DR1比虛設點圖案DP厚,且其厚度差的範圍為約10埃至約500埃。
As shown in FIGS. 28, 34, and 35, the memory cell array M is surrounded by the patterned
半導體基底100的表面S1與表面S2之間的水平高度差可減小形成在第一區100A上的記憶體單元陣列M與形成在周邊電路區100B2上的周邊電路P之間的閘極高度差。
The level difference between the surface S1 and the surface S2 of the
參照圖28與圖29,在半導體基底100上形成停止層(或稱為蝕刻停止層)180,以覆蓋記憶體單元陣列M、圖案化的導電層130c、第一虛設環DR1、第二虛設環DR2、虛設點圖案DP及周邊電路P。接著,在蝕刻停止層180上形成層間介電層(inter-layered dielectric layer,ILD)182。在一些實施例中,蝕刻停止層180的材料可包括氧化矽、氮化矽(SiN)或氮氧化矽(SiON),且層間介電層182的材料可包括磷矽玻璃(phosphosilicate glass,PSG)、硼磷矽酸鹽玻璃(borophosphosilicate glass,BPSG)或其類似物。蝕刻停止層180與層間介電層182的材料僅用於說明,且本揭露不限於此。
28 and 29, a stop layer (or etch stop layer) 180 is formed on the
參照圖29與圖30,對層間介電層182進行ILD研磨製程(例如,CMP製程),直到暴露出部分停止層180。在一些實施例中,在進行ILD研磨製程之後,覆蓋第一虛設環DR1的頂面、第二虛設環DR2的頂面、圖案化的導電層130c的頂面及記憶體單元陣列M的部分停止層180可暴露出來。在進行層間介電層182的研磨製程之後,形成經研磨的層間介電層182a,且在虛設點圖案DP及周邊電路P上方的區域內可能發生CMP凹陷。如圖30所示,產生由CMP凹陷導致的傾斜表面IS1。分佈在第二區100B上的第一虛設環DR1有助於控制CMP凹陷的擴展。舉例來說,由ILD研磨製程導致的傾斜表面IS1可被控制在第二區100B中。換句話說,CMP凹陷的擴展可被第一虛設環DR1控制,使得在進
行ILD研磨製程之後CMP凹陷可不擴展至第一區100A中。在省略了分佈於第二區100B上的第一虛設環DR1的情況下,在進行ILD研磨製程之後CMP凹陷可能會擴展到第一區100A中。
Referring to FIGS. 29 and 30, an ILD polishing process (for example, a CMP process) is performed on the
參照圖31,對停止層180進行停止層研磨製程(例如,CMP製程),直到記憶體單元陣列M的頂面、圖案化的導電層130c的頂面、第一虛設環DR1的頂面、第二虛設環DR2的頂面、虛設點圖案DP的頂面及周邊電路P的頂面暴露出來。在進行停止層180的研磨製程之後,形成經研磨並圖案化的停止層180a,且在半導體部分112、第一虛設環DR1、虛設點圖案DP以及周邊電路P上方的區域內可能發生CMP凹陷。如圖31所示,產生由CMP凹陷所導致的另一傾斜表面IS2。換句話說,與圖30相比,CMP凹陷擴展。
Referring to FIG. 31, a stop layer polishing process (eg, a CMP process) is performed on the
如圖31所示,在停止層180的研磨期間,由於第一虛設環DR1比虛設點圖案DP及周邊電路P厚,因此第一虛設環DR1可阻止由停止層研磨所導致的CMP凹陷的擴展,且凹陷的擴展可得到控制。在進行ILD研磨與停止層研磨之後,記憶體單元陣列M不受CMP凹陷現象的影響。在省略了分佈於第二區100B上的第一虛設環DR1的情況下,CMP凹陷可能在進行停止層180的研磨之後進一步擴展到第一區100A中。
As shown in FIG. 31, during the polishing of the
參照圖31與圖32,在一些實施例中,可進行閘極取代製程,以使用金屬閘極電極MG取代閘極電極152。在一些替代實施例中,可進行閘極取代製程,以分別使用金屬閘極電極MG與金屬圖案取代閘極電極152與虛設圖案156。在閘極取代製程期間,進行金屬閘極研磨(例如,CMP製程),且經研磨的層間介
電層182a被進一步研磨。在進行金屬閘極電極MG的研磨製程之後,在圖案化的導電層130c、半導體部分112、第一虛設環DR1、虛設點圖案DP及周邊電路P上方的區域內可能發生CMP凹陷。如圖32所示,產生由CMP凹陷所導致的傾斜表面IS3。換句話說,CMP凹陷進一步擴展。
Referring to FIGS. 31 and 32, in some embodiments, a gate replacement process may be performed to replace the
在進行ILD研磨、停止層研磨及金屬閘極電極MG的研磨之後,可形成圖案化的介電層(即,經研磨並圖案化的停止層180a與經研磨的層間介電層182a),以覆蓋半導體基底100。記憶體單元陣列M、周邊電路P、第一虛設環DR1及第二虛設環DR2嵌入於圖案化的介電層(即,經研磨並圖案化的停止層180a與經研磨的層間介電層182a)中。如圖31所示,第一虛設環DR1的頂面是傾斜的。此外,位於第一虛設環DR1與第二虛設環DR2之間的部分經研磨的層間介電層182a具有傾斜的頂面。
After performing ILD polishing, stop layer polishing, and metal gate electrode MG polishing, a patterned dielectric layer (ie, the polished and
如圖32所示,在金屬閘極電極MG的研磨期間,由於第一虛設環DR1與第二虛設環DR2比虛設點圖案DP及周邊電路P厚,因此第一虛設環DR1與第二虛設環DR2可阻止由金屬閘極電極MG的研磨所引起的CMP凹陷的進一步擴展,且CMP凹陷的擴展可得到控制。換句話說,在進行停止層180的研磨與金屬閘極電極MG的研磨之後,在第二區100B與第一溝渠隔離110a上方的區域內發生CMP凹陷,且所述凹陷不會擴展到影響記憶體單元陣列M。因此,記憶體單元陣列M不受ILD研磨、停止層研磨及閘極取代製程的影響。記憶體單元陣列M的良率因此增加。在省略了分佈於第二區100B上的第一虛設環DR1的情況下,記
憶體單元陣列M可能受到ILD研磨、停止層研磨及閘極取代製程的影響。
As shown in FIG. 32, during the polishing of the metal gate electrode MG, since the first dummy ring DR1 and the second dummy ring DR2 are thicker than the dummy dot pattern DP and the peripheral circuit P, the first dummy ring DR1 and the second dummy ring DR2 can prevent further expansion of the CMP depression caused by the grinding of the metal gate electrode MG, and the expansion of the CMP depression can be controlled. In other words, after the polishing of the
在進行停止層180的研磨與金屬閘極電極MG的研磨之後,第二虛設環DR2的厚度可大於第一虛設環DR1的厚度。至少一個第一虛設環DR1的厚度可大於虛設點圖案DP的厚度。周邊電路P的高度可大體上等於虛設點圖案DP的厚度。在一些實施例中,第一虛設環DR1的頂面與第二虛設環DR2的頂面可以是傾斜的表面。
After the grinding of the
在進行停止層180的研磨與金屬閘極電極MG的研磨之後,記憶體單元陣列M的高度大於周邊電路P的高度、第一虛設環DR1的厚度及第二虛設環DR2的厚度。記憶體單元陣列M的頂面高於周邊電路P的頂面,且記憶體單元陣列M的頂面可高於第一虛設環DR1的頂面及第二虛設環DR2的頂面。此外,第一虛設環DR1的頂面與第二虛設環DR2的頂面高於周邊電路P的頂面與虛設點圖案DP的頂面。
After the polishing of the
如圖26至圖32所示,第一部分150a與第二部分150b(圖26中所示)之間的厚度差導致第一虛設環DR1與虛設點圖案DP之間的厚度差。如圖30至圖32所示,在ILD 182、停止層180以及金屬閘極電極MG的研磨製程中,由於第一虛設環DR1與虛設點圖案DP之間的厚度差異,第一虛設環DR1可用作阻礙器(retarder),以阻止CMP凹陷不受控制的向記憶體單元陣列M擴展。因此,第一虛設環DR1可保護記憶體單元陣列M免受CMP凹陷的損壞。
As shown in FIGS. 26 to 32, the thickness difference between the
圖33是根據本揭露一些實施例的示意性地示出包括排列成陣列的多個積體電路構件的晶圓的上視圖;圖34是根據本揭露一些實施例的示意性地示出圖33中所示的部分X的放大上視圖。 33 is a top view schematically showing a wafer including a plurality of integrated circuit members arranged in an array according to some embodiments of the present disclosure; FIG. 34 is a schematic view showing FIG. 33 according to some embodiments of the present disclosure Enlarged top view of part X shown in.
參照圖32、圖33與圖34,上述半導體結構(圖32中所示)可以是圖33中所示的晶圓,且晶圓可包括排列成陣列的多個積體電路構件200。每個積體電路構件200可包括記憶體單元陣列M、圖案化的導電層130c、第一虛設環DR1(即,外虛設環)、第二虛設環DR2(即,內虛設環)、虛設點圖案DP及周邊電路P。從圖33所示的上視圖,圖案化的導電層130c、第一虛設環DR1、半導體部分112及第二虛設環DR2為環形結構。記憶體單元陣列M被圖案化的導電層130c、第一虛設環DR1、半導體部分112及第二虛設環DR2環繞。圖案化的導電層130c與第二虛設環DR2設置於第一溝渠隔離110a上,且第一虛設環DR1與虛設點圖案DP設置於第二溝渠隔離110b上。虛設點圖案DP分佈在第一虛設環DR1與周邊電路P之間。
Referring to FIGS. 32, 33, and 34, the above semiconductor structure (shown in FIG. 32) may be the wafer shown in FIG. 33, and the wafer may include a plurality of
圖35是根據本揭露一些替代實施例的示意性地示出圖33中所示的部分X的放大上視圖。 FIG. 35 is an enlarged top view schematically showing part X shown in FIG. 33 according to some alternative embodiments of the present disclosure.
參照圖33、圖34與圖35,圖35中所示的積體電路構件200a與圖34中所示的積體電路構件200類似,不同之處在於,在圖35中形成了兩個第一虛設環DR1。第一虛設環DR1的數量在本申請中不受限制。此外,每個第一虛設環DR1的線寬(linewidth)在本申請中不受限制。
Referring to FIGS. 33, 34, and 35, the
在上述實施例中,使用第一元件(例如,記憶體單元陣列M)與第二元件(例如,周邊電路P)之間的至少一個虛設環來最小化由研磨制程產生的副作用。因此,可很好地保護第一元件(例如,記憶體單元陣列M),並可提高製造良率。 In the above embodiment, at least one dummy ring between the first element (for example, the memory cell array M) and the second element (for example, the peripheral circuit P) is used to minimize the side effects caused by the polishing process. Therefore, the first element (for example, the memory cell array M) can be well protected, and the manufacturing yield can be improved.
根據本揭露的一些實施例,提供一種半導體結構,其包括半導體基底與至少一個圖案化的介電層。半導體基底包括半導體部分、至少一個第一元件、至少一個第二元件與至少一個第一虛設環。至少一個第一元件設置於被半導體部分環繞的第一區。至少一個第二元件與至少一個第一虛設環設置於第二區上,且第二區環繞第一區。至少一個圖案化的介電層覆蓋半導體基底。 According to some embodiments of the present disclosure, a semiconductor structure is provided, which includes a semiconductor substrate and at least one patterned dielectric layer. The semiconductor substrate includes a semiconductor portion, at least one first element, at least one second element, and at least one first dummy ring. At least one first element is disposed in the first region surrounded by the semiconductor portion. At least one second element and at least one first dummy ring are disposed on the second area, and the second area surrounds the first area. At least one patterned dielectric layer covers the semiconductor substrate.
在上述半導體結構中,至少一個第一元件的第一高度大於至少一個第二元件的第二高度及至少一個第一虛設環的第一厚度,且第一厚度大於第二高度。 In the above semiconductor structure, the first height of at least one first element is greater than the second height of at least one second element and the first thickness of at least one first dummy ring, and the first thickness is greater than the second height.
在上述半導體結構中,至少一個第一虛設環是電性浮置的。 In the above semiconductor structure, at least one first dummy ring is electrically floating.
在上述半導體結構中,至少一個第一虛設環具有傾斜的頂面。 In the above semiconductor structure, at least one first dummy ring has an inclined top surface.
在上述半導體結構中,更包括至少一個第二虛設環,設置於第一區上,其中至少一個第一虛設環與至少一個第二虛設環環繞至少一個第一元件,且至少一個第二虛設環比至少一個第一虛設環厚。 The above semiconductor structure further includes at least one second dummy ring disposed on the first region, wherein at least one first dummy ring and at least one second dummy ring surround at least one first element, and at least one second dummy ring is At least one first dummy ring thickness.
根據本揭露的一些實施例,提供一種半導體結構,其包括半導體基底與至少一個圖案化的介電層。半導體基底包括主動區與環繞主動區的周邊區、設置於主動區上的至少一個第一元 件、設置於周邊區上的至少一個第二元件以及設置於周邊區上的至少一個第一虛設環。至少一個第一元件與至少一個第二元件被主動區的半導體部分間隔開。至少一個圖案化的介電層設置於半導體基底上。至少一個第一元件、至少一個第二元件及至少一個第一虛設環嵌入於圖案化的介電層中。 According to some embodiments of the present disclosure, a semiconductor structure is provided, which includes a semiconductor substrate and at least one patterned dielectric layer. The semiconductor substrate includes an active area and a peripheral area surrounding the active area, and at least one first element disposed on the active area Pieces, at least one second element disposed on the peripheral area, and at least one first dummy ring disposed on the peripheral area. At least one first element and at least one second element are spaced apart by the semiconductor portion of the active region. At least one patterned dielectric layer is disposed on the semiconductor substrate. At least one first element, at least one second element, and at least one first dummy ring are embedded in the patterned dielectric layer.
在上述半導體結構中,至少一個第一元件的第一高度大於至少一個第二元件的第二高度及至少一個第一虛設環的第一厚度,且第一厚度大於第二高度。 In the above semiconductor structure, the first height of at least one first element is greater than the second height of at least one second element and the first thickness of at least one first dummy ring, and the first thickness is greater than the second height.
在上述半導體結構中,至少一個第一虛設環是電性浮置的。 In the above semiconductor structure, at least one first dummy ring is electrically floating.
在上述半導體結構中,至少一個第一虛設環具有傾斜的頂面。 In the above semiconductor structure, at least one first dummy ring has an inclined top surface.
在上述半導體結構中,更包括至少一個第二虛設環,設置於主動區上,其中至少一個第一虛設環與至少一個第二虛設環環繞至少一個第一元件,且至少一個第二虛設環比至少一個第一虛設環厚。 The above semiconductor structure further includes at least one second dummy ring disposed on the active region, wherein at least one first dummy ring and at least one second dummy ring surround at least one first element, and at least one second dummy ring is more than A first dummy ring is thick.
在上述半導體結構中,半導體基底更包括嵌入於主動區中的第一溝渠隔離以及嵌入於周邊區中的第二溝渠隔離,半導體部分位於第一溝渠隔離與第二溝渠隔離之間,且至少一個第一虛設環設置於第二溝渠隔離上。 In the above semiconductor structure, the semiconductor substrate further includes a first trench isolation embedded in the active area and a second trench isolation embedded in the peripheral area, the semiconductor portion is located between the first trench isolation and the second trench isolation, and at least one The first dummy ring is disposed on the second trench isolation.
在上述半導體結構中,更包括至少一個第二虛設環,設置於第一溝渠隔離上,其中至少一個第一虛設環與至少一個第二虛設環環繞至少一個第一元件,且至少一個第二虛設環比至少一個第一虛設環厚。 The above semiconductor structure further includes at least one second dummy ring disposed on the first trench isolation, wherein at least one first dummy ring and at least one second dummy ring surround at least one first element, and at least one second dummy The ring is thicker than at least one first dummy ring.
根據本揭露的一些實施例,提供一種半導體結構的製造方法,其包括以下步驟。提供具有半導體部分的半導體基底。在被半導體部分環繞的第一區上形成至少一個第一元件。在第二區上形成至少一個第二元件與至少一個第一虛設環,其中第二區環繞第一區,且至少一個第一虛設環環繞至少一個第一元件。在半導體基底上形成至少一個介電層,以覆蓋至少一個第一元件、至少一個第二元件以及至少一個第一虛設環。研磨至少一個介電層,直到至少一個第一元件、至少一個第二元件以及至少一個第一虛設環暴露出來。 According to some embodiments of the present disclosure, a method for manufacturing a semiconductor structure is provided, which includes the following steps. A semiconductor substrate having a semiconductor portion is provided. At least one first element is formed on the first region surrounded by the semiconductor portion. At least one second element and at least one first dummy ring are formed on the second area, wherein the second area surrounds the first area, and at least one first dummy ring surrounds at least one first element. At least one dielectric layer is formed on the semiconductor substrate to cover at least one first element, at least one second element, and at least one first dummy ring. Grind at least one dielectric layer until at least one first element, at least one second element, and at least one first dummy ring are exposed.
在上述半導體結構的製造方法中,其中在研磨至少一個介電層之後,至少一個第一虛設環被部分研磨,使得至少一個第一元件的第一高度大於至少一個第二元件的第二高度以及至少一個第一虛設環的第一厚度,且第一厚度大於第二高度。 In the above method of manufacturing a semiconductor structure, wherein after grinding at least one dielectric layer, at least one first dummy ring is partially ground so that the first height of at least one first element is greater than the second height of at least one second element and The first thickness of the at least one first dummy ring is greater than the second height.
在上述半導體結構的製造方法中,其中在研磨至少一個介電層之前,至少一個第一虛設環包括大體上平坦的頂面,且在研磨至少一個介電層之後,至少一個第一虛設環包括傾斜的頂面。 In the above method of manufacturing a semiconductor structure, wherein before grinding at least one dielectric layer, at least one first dummy ring includes a substantially flat top surface, and after grinding at least one dielectric layer, at least one first dummy ring includes Inclined top surface.
在上述半導體結構的製造方法中,更包括在第二區的第二溝渠隔離上形成多個虛設點圖案,其中至少一個第一虛設環位於至少一個第一元件與多個虛設點圖案之間,且至少一個第一虛設環比多個虛設點圖案厚。 In the above method for manufacturing a semiconductor structure, the method further includes forming a plurality of dummy dot patterns on the second trench isolation in the second region, wherein at least one first dummy ring is located between the at least one first element and the plurality of dummy dot patterns, And at least one first dummy ring is thicker than a plurality of dummy dot patterns.
在上述半導體結構的製造方法中,更包括在第一區的第一溝渠隔離上形成至少一個第二虛設環,其中至少一個第二虛設環環繞至少一個第一元件,且至少一個第二虛設環的第二厚度大於至少一個第一虛設環的第一厚度。 In the above method for manufacturing a semiconductor structure, it further includes forming at least one second dummy ring on the first trench isolation in the first region, wherein at least one second dummy ring surrounds at least one first element, and at least one second dummy ring The second thickness is greater than the first thickness of the at least one first dummy ring.
在上述半導體結構的製造方法中,其中在第二區上形成至少一個第二元件與至少一個第一虛設環包括:在第二區形成介電層,介電層包括第一部分與第二部分,且第一部分比第二部分厚;在介電層的第一部分上形成多個堆疊虛設圖案;形成設置於介電層的第二部分上的閘極電極以及堆疊於閘極電極上的介電頂蓋;以及使用堆疊虛設圖案、閘極電極以及介電頂蓋作為罩幕來圖案化介電層,以在堆疊虛設圖案下形成第一介電圖案,以及在閘極電極下形成第二介電圖案,其中形成了包括第一介電圖案與堆疊虛設圖案的至少一個第一虛設環,以及包括第二介電圖案、閘極電極以及介電頂蓋的至少一個第二元件。 In the above method for manufacturing a semiconductor structure, wherein forming at least one second element and at least one first dummy ring on the second region includes: forming a dielectric layer on the second region, the dielectric layer includes a first portion and a second portion, And the first part is thicker than the second part; a plurality of stacked dummy patterns are formed on the first part of the dielectric layer; a gate electrode provided on the second part of the dielectric layer and a dielectric top stacked on the gate electrode are formed A cover; and using a stacked dummy pattern, a gate electrode, and a dielectric cap as a mask to pattern the dielectric layer to form a first dielectric pattern under the stacked dummy pattern, and a second dielectric under the gate electrode In the pattern, at least one first dummy ring including the first dielectric pattern and the stacked dummy pattern is formed, and at least one second element including the second dielectric pattern, the gate electrode, and the dielectric cap.
在上述半導體結構的製造方法中,其中第一部分與第二部分之間的厚度差的範圍為約10埃至約500埃。 In the above method of manufacturing a semiconductor structure, the thickness difference between the first portion and the second portion ranges from about 10 angstroms to about 500 angstroms.
在上述半導體結構的製造方法中,其中第一區的邊界至第一部分的外邊界之間的距離的範圍為約0.1微米至約50微米。 In the above method of manufacturing a semiconductor structure, the distance between the boundary of the first region and the outer boundary of the first portion ranges from about 0.1 micrometer to about 50 micrometers.
以上概述了若干實施例的特徵,以使所屬領域中的技術人員可更好地理解本揭露的各個方面。所屬領域中的技術人員應知,他們可容易地使用本揭露做為設計或修改其他製程及結構的基礎來施行與本文中所介紹的實施例相同的目的及/或實現與本文中所介紹的實施例相同的優點。所屬領域中的技術人員還應認識到,這些等效構造並不悖離本揭露的精神及範圍,而且他們可在不悖離本揭露的精神及範圍的條件下對其作出各種改變、代替及變更。 The above outlines the features of several embodiments so that those skilled in the art can better understand the various aspects of the present disclosure. Those skilled in the art should understand that they can easily use the present disclosure as a basis for designing or modifying other processes and structures to perform the same purposes and/or achieve the same goals and/or implementations as the embodiments described herein. The same advantages as the embodiment. Those skilled in the art should also realize that these equivalent structures do not deviate from the spirit and scope of this disclosure, and they can make various changes, substitutions, and substitutions without departing from the spirit and scope of this disclosure. change.
100‧‧‧半導體基底 100‧‧‧Semiconductor substrate
100A‧‧‧第一區 100A‧‧‧District 1
100B‧‧‧第二區
100B‧‧‧
110a‧‧‧第一溝渠隔離 110a‧‧‧The first trench isolation
110b‧‧‧第二溝渠隔離 110b‧‧‧Second trench isolation
112‧‧‧半導體部分 112‧‧‧Semiconductor
130c‧‧‧圖案化的導電層 130c‧‧‧patterned conductive layer
180a‧‧‧圖案化的停止層 180a‧‧‧patterned stop layer
182a‧‧‧經研磨的層間介電層 182a‧‧‧polished interlayer dielectric layer
DP‧‧‧虛設點圖案 DP‧‧‧Dummy dot pattern
DR1‧‧‧第一虛設環 DR1‧‧‧The first dummy ring
DR2‧‧‧第二虛設環 DR2‧‧‧The second dummy ring
IS3‧‧‧傾斜表面 IS3‧‧‧inclined surface
M‧‧‧記憶單元陣列 M‧‧‧Memory cell array
MG‧‧‧金屬閘極電極 MG‧‧‧Metal gate electrode
P‧‧‧周邊電路 P‧‧‧Peripheral circuit
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