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Device and method for reducing contact resistance of a metal

專利號
US11177168B2
公開日期
2021-11-16
申請人
Taiwan Semiconductor Manufacturing Company, Ltd.(TW Hsinchu)
發(fā)明人
Ya-Lien Lee; Hung-Wen Su; Kuei-Pin Lee; Yu-Hung Lin; Yu-Min Chang
IPC分類
H01L21/768; H01L23/532; H01L23/50; H01L21/285
技術(shù)領(lǐng)域
pvd,trench,tan,layer,ta,barrier,dielectric,ald,in,depositing
地域: Hsinchu

摘要

A method includes forming a trench in a low-K dielectric layer, where the trench exposes an underlying contact area of a substrate. A first tantalum nitride (TaN) layer is conformally deposited within the trench, where the first TaN layer is deposited using atomic layer deposition (ALD) or chemical vapor deposition (CVD). A tantalum (Ta) layer is deposited on the first TaN layer conformally within the trench, where the Ta layer is deposited using physical vapor deposition (PVD). An electroplating process is performed to deposit a conductive layer over the Ta layer. A via is formed over the conductive layer, where forming the via includes depositing a second TaN layer within the via and in contact with the conductive layer.

說明書

PRIORITY DATA

This application is a continuation of U.S. patent application Ser. No. 15/894,051, filed Feb. 12, 2018, which will issue as U.S. Pat. No. 10,276,431, which is a continuation of U.S. patent application Ser. No. 14/879,992 filed on Oct. 9, 2015, now issued U.S. Pat. No. 9,892,963, which is a divisional application of U.S. patent application Ser. No. 14/286,859 filed on May 23, 2014, now issued U.S. Pat. No. 9,159,666, which is a continuation-in-part of U.S. patent application Ser. No. 13/601,223 filed on Aug. 31, 2012, now issued U.S. Pat. No. 8,736,056, which in turn claims priority to U.S. Provisional Patent Application Ser. No. 61/677,862 filed on Jul. 31, 2012 and entitled “A Method of Reducing Contact Resistance of a Metal.” The entire disclosure of the above applications is incorporated herein by reference.

BACKGROUND

The semiconductor integrated circuit (IC) industry has experienced exponential growth. Technological advances in IC materials and design have produced generations of ICs where each generation has smaller and more complex circuits than the previous generation. In the course of IC evolution, functional density (i.e., the number of interconnected devices per chip area) has generally increased while geometry size (i.e., the smallest component (or line) that can be created using a fabrication process) has decreased. This scaling down process generally provides benefits by increasing production efficiency and lowering associated costs. Such scaling down has also increased the complexity of processing and manufacturing ICs and, for these advances to be realized, similar developments in IC processing and manufacturing are needed.

權(quán)利要求

1
What is claimed is:1. A method, comprising:forming a trench in a low-K dielectric layer, wherein the trench exposes an underlying contact area of a substrate;depositing a first tantalum nitride (TaN) layer conformally within the trench, wherein the first TaN layer is deposited using atomic layer deposition (ALD);depositing a second TaN layer on the first TaN layer conformally with the trench, wherein the second TaN layer is deposited using a different process than the process used to deposit the first TaN layer;depositing a tantalum (Ta) layer on the second TaN layer conformally within the trench, wherein the Ta layer is deposited using physical vapor deposition (PVD);performing an electroplating process to deposit a conductive layer over the Ta layer; andforming a via over the conductive layer, wherein forming the via includes depositing a third TaN layer within the via and in contact with the conductive layer, and wherein the third TaN layer is deposited using ALD;wherein the depositing the first TaN layer and the second TaN layer forms an α-Ta component that spans across a respective thickness of each of the first TaN layer and the second TaN layer.2. The method of claim 1, wherein the first TaN layer and the third TaN layer have a greater concentration of nitrogen than tantalum.3. The method of claim 1, wherein the low-K dielectric layer is disposed at least partially over a silicon nitride cap layer.4. The method of claim 1, wherein an N/Ta ratio of the first TaN layer and the third TaN layer ranges from 2.3 to 2.6.5. The method of claim 1, wherein the depositing of the first TaN layer and the third TaN layer includes plasma sputtering a Ta target with a nitrogen (N2) flow of at least 20 Standard Cubic Centimeters per Minute (sccm).6. The method of claim 1, wherein the first TaN layer and the third TaN layer are deposited to have a thickness ranging from 5 to 10 angstrom (?).7. The method of claim 1, wherein the Ta layer is deposited to have a thickness ranging from 50 to 100 ?.8. The method of claim 1, wherein the performing the electroplating process includes depositing a seed layer prior to depositing the conductive layer.9. The method of claim 1, wherein the conductive layer includes copper (Cu).10. A method, comprising:depositing a dielectric layer on a substrate;forming an opening in the dielectric layer;depositing a first tantalum nitride (TaN) layer within the opening such that the first TaN layer has a greater concentration of nitrogen than tantalum;performing a plurality of physical vapor deposition (PVD) processes to deposit a second TaN layer on the first TaN layer and a tantalum (Ta) layer on the second TaN layer, wherein a controlled nitrogen flow during deposition of the second TaN layer provides for formation of an α-Ta component that spans from a top surface of the second TaN layer to a bottom surface of the second TaN layer; anddepositing a metal layer over the PVD-deposited Ta layer.11. The method of claim 10, wherein the dielectric layer includes a low-K dielectric layer.12. The method of claim 10, wherein the depositing of the first TaN layer includes plasma sputtering a Ta target with a nitrogen (N2) flow ranging from 20 sccm to 40 sccm.13. The method of claim 10, wherein an overall carbon (C) concentration of the first TaN layer and the Ta layer is less than 0.2 percent (%).14. The method of claim 10, wherein the first TaN layer is deposited to have a thickness ranging from 10 to 20 angstrom (?).15. The method of claim 10, wherein the Ta layer is deposited to have a thickness ranging from 50 to 100 ?.16. The method of claim 10, wherein the metal layer includes an electroplated metal layer.17. The method of claim 16, wherein the electroplated metal layer includes copper (Cu).18. A method, comprising:forming a trench in a low-K dielectric layer;conformally depositing a first tantalum nitride (TaN) layer on a side wall of the trench using atomic layer deposition (ALD);depositing a second TaN layer on the first TaN layer using a first physical vapor deposition (PVD) process, wherein the second TaN layer includes an α-Ta component that spans from the top surface to the bottom surface of the second TaN layer; anddepositing a tantalum (Ta) layer on the second TaN layer using a second PVD process;wherein an overall carbon (C) concentration of the first TaN layer and the Ta layer is less than 0.2 percent (%).19. The method of claim 18, wherein an N/Ta ratio of the first TaN layer ranges from 2.3 to 2.6.20. The method of claim 18, wherein the first TaN layer is deposited to have a thickness ranging from 5 to 10 angstrom (?), and the Ta layer is deposited to have a thickness ranging from 50 to 100 ?.
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