Abstract:
An interlayer connector for preventing delamination of semiconductor layers, and methods of forming the connector are disclosed. The connector includes a first connector head in a first distal layer, a second connector head in a second distal layer and a connector body coupling the first and second connector heads. Each connector head has a dimension greater is size than the connector body such that the layers are securely held together. The interlayer connector may be isolated from current-carrying wiring or provided in the form of a contact via. The interlayer connector provides a mechanical mechanism to prevent layers from delaminating regardless of the materials used. The invention also eliminates the need for white space fill above and below via fill by using the connectors coplanar with the on device wiring.

Description:
BACKGROUND OF INVENTION 
   1. Technical Field 
   The present invention relates generally to semiconductor devices, and more particularly, to an interlayer connector for preventing delamination of layers of a semiconductor device, and methods of forming the connector. 
   2. Related Art 
   Semiconductor fabricators are increasingly facing challenges relative to delamination of layers within a semiconductor device. One reason for the increased significance of this issue is that the industry is currently turning to the use of lower dielectric constant (low-k) dielectric materials to lower capacitances in the continuous pursuit of smaller semiconductor devices. Some of these low-k dielectric materials include SiLK™ from Dow Chemical, Coral™ from Novellus Systems and Black Diamond™ from Applied Materials. Delamination issues arise relative to these materials because they are extremely difficult to integrate with other materials. For example, it is very difficult to attain good adhesion between interfaces of different materials where the materials include a low-k dielectric. The poor adhesion of the new low-k materials is present relative to other dielectrics and metal. As a result of the poor adhesive properties, widespread use of these materials must overcome the delamination problem. Conventionally, adhesion promoters or treatments have been applied to decrease the likelihood that delamination will occur between interfaces. In cases of some of the newer low-k dielectrics, however, this approach does not work. 
   Another challenge relative to addressing the low-k dielectric material delamination problem is that the semiconductor industry is currently undecided in terms of which type of material will ultimately be favored. For example, the integrated circuit (IC) industry is pursuing parallel paths regarding use of chemical vapor deposited (CVD) materials such as Coral and Black Diamond, and spin-on dielectrics such as SiLK. Each category of material presents its own problems relative to the adhesion/delamination problem. For example, to lower the dielectric constant of CVD materials, carbon has been substituted in the form of methyl groups (CH x ) for oxygen in silicon dioxide. However, the carbon addition creates more adhesion problems, and requires more specialized processing. Other low-k materials may not pose this problem, but present other issues relative to delamination. As a result, addressing the delamination problem is difficult because any solution must address the varying challenges of each low-k material that may eventually find widespread use. 
   Further delamination problems are presented by back-end-of-line (BEOL) low-k dielectrics that have very high coefficient of thermal expansion (CTE) as compared to the on device wiring and substrate. In particular, the CTE mismatch causes yield and reliability problems as the device or wafer is thermally cycled up and down in temperature. For example, devices are stressed at temperature ranges of approximately −150° C. to +150° C. For dielectrics such as polyarylene ether (i.e., SiLK or Flare™ by Honeywell), the stressing has led to catastrophic device fails during stressing due to poor via to wire resistance after stressing (i.e. via opens). One partial solution to this problem has been to add via fill to the existing white space wire fill used on a device. That is, instead of simple wire fill in the white space, providing vias also. With via fill, white-space-fill wire shapes are connected together by vias to connect the wiring layers together and reduce the CTE mismatch induced expansion and contraction during thermal cycling. See, for example, U.S. Pat. No. 6,559,543 to Dunham et al., and assigned to the assignee of the present application, International Business Machines (IBM). One problem with via fill, however, is that it is only usable when white space wire fill shapes are stacked on top of each other, which only occurs on wiring levels with low wiring density. Another problem with via fill is that they are subject to the same stresses as active vias and can de-adhere form underlying metal. Accordingly, this approach finds limited applicability. 
   In view of the foregoing, there is a need in the art for an improved mechanism to prevent interlayer delamination that addresses the problems of the related art. 
   SUMMARY OF INVENTION 
   The invention includes an interlayer connector for preventing delamination of semiconductor layers, and methods of forming the connector. The connector includes a first connector head in a first distal layer, a second connector head in a second distal layer and a connector body coupling the first and second connector heads. Each connector head has a dimension greater is size than the connector body such that the layers are securely held together. The interlayer connector may be isolated from current-carrying wiring or provided in the form of a contact via. The interlayer connector provides a mechanical mechanism to prevent layers from delaminating regardless of the materials used. The invention also eliminates the need for white space fill above and below via fill by using the connectors coplanar with the on device wiring. 
   A first aspect of the invention is directed to a method of forming an interlayer connector for use in a semiconductor device, the method comprising the steps of: forming at least one opening including: a main body; a first connector head area in a dielectric area of a first distal layer, the first connector head area extending laterally beyond the main body, and a second connector head area in a second distal layer, the second connector head area extending laterally beyond the main body; and filling each opening to form the interlayer connector. 
   A second aspect of the invention is directed to a method for preventing delamination of at least two layers of a semiconductor device, the method comprising the steps of: forming a first connector head in a dielectric area of a first distal layer of the at least two layers of the semiconductor device; forming a connector body coupled to the first connector head; and forming a second connector head in a second distal layer of the at least two layers of the semiconductor device, the second connector head being coupled to the connector body, wherein the first and second connector head each have a portion that extends laterally beyond the connector body. 
   A third aspect of the invention is directed to an interlayer connector for preventing delamination of at least two layers of a semiconductor device, the connector comprising: a first connector head located in a dielectric area of a first distal layer of the at least two layers of the semiconductor device; a connector body coupled to the first connector head; and a second connector head coupled to the connector body and located in a second distal layer of the at least two layers of the semiconductor device, the second connector head extending over the connector body. 
   The foregoing and other features of the invention will be apparent from the following more particular description of embodiments of the invention. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
     The embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like elements, and wherein: 
       FIGS. 1A–1B  shows a cross-section and plan view, respectively, of an interlayer connector for preventing delamination of at least two layers of a semiconductor device according to the invention. 
       FIG. 2  shows an alternative embodiment of interlayer connectors. 
       FIGS. 3–6  show a first step of a method for forming the interlayer connectors of  FIG. 1 . 
       FIGS. 7–8  show a second step of the method. 
       FIG. 9  shows interlayer connectors of  FIG. 1  applied across multiple wiring levels of a semiconductor device. 
   

   DETAILED DESCRIPTION 
   With reference to the accompanying drawings,  FIG. 1A  shows a cross-sectional view of a semiconductor device  90  including a number of interlayer connectors  100 A,  100 B (hereinafter “connectors”) for preventing delamination of at least two layers of the semiconductor device according to the invention.  FIG. 1B  shows a plan view of the same structure. In the embodiment shown, semiconductor device  90  includes a first distal layer  106 , at least one cover layer  108 , and a second distal layer  122 . It should be recognized, however, that device  90  may include practically any number of layers. A hard mask layer atop second distal layer  122  has been omitted for clarity purposes. Furthermore, the layers may include practically any material used in semiconductor fabrication, for example, dielectric material such as silicon dioxide (SiO 2 ), cap material such as silicon nitride (SiN) or silicon carbide (SiC), low-k dielectric material such as SiLK, Coral or Black Diamond, or metal such as copper (Cu) or aluminum (Al). In any event, connector  110  prevents delamination of the layers. As used herein, “distal layer” designates an uppermost or lowermost layer to which the connector is to be applied, and “cover layer” designates a cap layer  124  of, for example, silicon nitride (SiN), silicon carbide (SiC) or silicon-carbon-nitrogen (SiCN), or a hard mask layer  126 . Hard mask layer  126  is substantially coplanar with an uppermost surface of damascene wires  132 A,  132 B. In the embodiments described herein, distal layer is described as a dielectric layer. It should be recognized, however, that a distal layer may also be a metal layer, if desired. 
   Each connector  100 A,  100 B includes: a first connector head  102  located in a dielectric area  104  of first distal layer  106  of the at least two layers of semiconductor device  90 , a connector body  110  coupled to first connector head  102 , and a second connector head  120  coupled to connector body  110  and located in second distal layer  122  of the at least two layers of semiconductor device  90 . As illustrated, each connector head  102 ,  120  includes a portion  130  that extends laterally beyond connector body  110 , which prevents layers  106 ,  108  and  120  from being pulled apart. In one embodiment, first connector head  102  undercuts cover layers  108  (i.e., extends laterally beyond connector body  110 ), and second connector head  120  includes a portion that overhangs (i.e., extends laterally beyond) connector body  110 . 
   In one embodiment, as shown on the left side of  FIGS. 1A–1B , a connector  100 A can be formed such that it is electrically isolated from current-carrying wiring  132 A,  132 B. That is, connector  100 A provides no other function than as interlayer connectors. Alternatively, as shown on the right side of  FIGS. 1A–1B , a connector  100 B can be partially landed on a current-carrying wire  132  in first distal layer  106 , and may include a metal so as to provide a contact via. In this case, the partial landing on current-carrying wire  132 B allows formation of first connector head  102 B as an undercut to cover layers  108 , which prevents connector head  102 B from being pulled out of first distal layer  106 . A conventional fully-landed dual damascene via  112  to wire  132 A is shown in the center of  FIGS. 1A–1B . Connectors  100 A and  100 B can be formed independently or in a single step, as will be described further below. Connector  100 A can be formed as part of an active wire or as a pure dummy connector (isolated from active wires). Similarly, connector  100 B can be formed as part of an active wire with via  110  that also functions as a connector head, or connector  100 B can be formed as a pure dummy connector. 
   As shown in  FIG. 2 , in an alternative embodiment, for, e.g., a device edge seal, a plurality of first connector heads  202  can be provided that are substantially or completely contiguous. In addition, a plurality of second connector heads  220  can be provided that are substantially or completely contiguous. A plurality of connector bodies  210  may be provided to couple the plurality of first connector heads  202  to plurality of second connector heads  220  provides structural rigidity (e.g., that prevents delamination along a device edge seal). The  FIG. 2  embodiment could also be extended to be a multiple vertically-stacked ladder structure (not shown) sharing the rails and staggering rungs across multiple layers. 
   Turning to  FIGS. 3–8 , a first embodiment of a method of forming connector  100 A,  100 B for use in semiconductor device  90  will now be described. In general, the method includes a first step of forming an opening for generation of an interlayer connector, and then filling the opening. It should be recognized that the center part of  FIGS. 3–8  illustrate formation of conventional dual damascene via  112  ( FIG. 1 ) to wire  132 A and wires  140  ( FIG. 1B  only), which may be formed simultaneously with connectors  100 A,  100 B of the invention. That is, interlayer connector  100 A,  100 B may be formed simultaneously with via  112  and wires  140 , as shown in  FIG. 1B . Connector head areas  158 A,  158 B ( FIGS. 3–6 ) of an interlayer connectors  100 A,  100 B may connect to a via  112  or a wire  140 . 
   In a first step, as shown in  FIGS. 3–6 , at least one opening  150 A,  150 B is formed. As will become more apparent, openings  150 A,  150 B can either land on device areas with no wires below or partially on wires below. As shown in  FIG. 6  only, each opening  150 A,  150 B ultimately includes a main body  152 A,  152 B, a first connector head area  154 A,  154 B in dielectric area  104  of first distal layer  106  and a second connector head area  158 A,  158 B in second distal layer  122 . Second connector head area  158 A,  158 B may also act as damascene wires  140  ( FIG. 1B ), and opening  152 B can act as an active via. Each first connector head area  154 A,  154 B includes at least one portion  160  that extends laterally beyond main body  152 A,  152 B. Similarly, each second connector head area  158 A,  158 B includes at least one portion  162  that extends laterally beyond main body  152 A,  152 B. Main body  152 A,  152 B extends through any intermediate overlying layers. In one embodiment, overlying layers include cover layers  108  of first distal layer  106  such as a cap layer  124  or a hard mask layer  126 , which may include one or more of silicon carbide (SiC), silicon-carbon-nitrogen (SiCN), hydrogenated silicon oxycarbide (SiCOH), silicon dioxide (SiO 2 ), silicon nitride (SiN), etc. Along with formation of openings  150 A,  150 B for formation of interlayer connectors  100  ( FIG. 1 ), other opening(s)  150 C each including a main body  152 C may be formed for constructing conventional fully-landed dual damascene vias  112  ( FIG. 1 ). 
   Returning to  FIGS. 3–5 , details of one embodiment of forming openings  150 A,  150 B will now be discussed. In  FIG. 3 , formation of each opening  150 A–C may be initiated by conducting one or more depositions and dual damascene patterning of a photoresist mask (not shown) and etching to form main bodies  152 A–C in layers  122 ,  124 , and second connector head areas  158 A,  158 B, as known in the art. In this step, cap layer  124  is opened. In  FIG. 4 , an optional thin (1–50 nm) liner  170  composed of, for example, one or more layers of tantalum-nitride (TaN)(preferred), titanium-nitride (TiN), tungsten-nitride (WN), tantalum (Ta), tungsten or other liner material is deposited. The deposition may use, for example, physical vapor deposition (PVD), ionized PVD, self-ionized plasma (SIP), chemical vapor deposition (CVD), atomic layer deposition (ALD), etc., as known in the art. In  FIG. 5 , an etching to remove liner  170  from flat wafer surfaces and remove hard mask  124  at the bottom of openings  150 A– 150 C is conducted. The etching may include a sputter etchback or any anisotropic etch, and may be performed in situ during layer  170  deposition (preferred). Next, layer  126  at the bottom of openings  152 A,  152 B is etched either as part of the etching of layer  170  or as a separate etching or sputtering step. 
   In a next step, shown in  FIG. 6 , a first connector head area  154 A,  154 B is formed in first distal layer  106  such that each area  154 A,  154 B extends laterally beyond main body  152 A,  152 B. In the embodiment shown, each first connector head area  154 A,  154 B undercuts at least one cover layer  108  positioned over first distal layer  106 . This step may include conducting an isotropic etch, preferably in-situ in the sputter etchback chamber immediately after the sputter etchback is complete. That is, before any liner/seed/plating deposition used for metallization of the wires and vias occurs. If the dielectric to be etched is silicon-based, such as SiCOH or porous SiCOH, the etch may include, for example, a short diluted hydrofluoric acid (DHF)(e.g., 100:1H 2 O:HF) wet etch. This isotropic etch would preferentially etch: first distal layer  106  (i.e., dielectric area  104  thereof) forming an undercut of hard mask  126  or hard mask  126  forming an undercut, or a combination thereof. To achieve lateral etching of hard mask  126 , an etch selective to dielectric area  104  and other exposed hard masks  126  is employed. For example, if dielectric area  104  includes a low-k material such as SiLK, plasma etching containing one or more of hydrogen (H 2 ), argon (Ar), oxygen (O 2 ) or nitrogen (N 2 ), etc., plasma, as known in the art, may be employed to laterally etch. If alternating hard mask materials are used, mutually exclusive etch processes between levels may be employed. 
   In some circumstances, special processing may be necessary to adequately form first and second connector head areas  154 A,  154 B,  158 A,  158 B. For example, in the case that dielectric area  104  includes SiCOH, etching to form areas  154 A,  154 B is difficult. In particular, SiCOH has a low etch rate of approximately 7 Angstroms/minute (Ang/min), for example, using a diluted hydro-fluoric acid (DHF) solution. In order to address this problem, in an alternative embodiment shown in  FIG. 5 , an oxidization  180  may be applied to openings  150 A,  150 B to convert the SiCOH to a more silicon-oxide-like material to increase an etch rate thereof, i.e., the etch rate of SiO in the same DHF solution is approximately 20–25 Ang/min. In addition, where second distal layer  122  includes SiCOH, this layer must be passivated or lined to protect it from the oxidative plasma, which could cause blowout in openings  150 A,  150 B in second distal layer  122 . In this case, a protective layer may be provided in openings  150 A,  150 B. The protective layer would be incident with the previously described liner  170 , shown in  FIG. 5 , and may be provided as any material capable of protecting layer  122  from the oxidation. In one embodiment, the protective layer may be provided as the previously described liner material. Alternatively, a polymer deposition could be performed at the end of a reactive ion etch (RIE) process shown in  FIG. 3  by using a plasma, e.g., a CF 4  rich plasma, to line and protect openings  150 A,  150 B in second distal layer  122  during the oxidation step. 
   In an alternative embodiment, an additional thin-film sub layer (not shown) may be employed, which might also double as an adhesion improvement layer for a subsequent layer, and also as an etch stop for chemical mechanical polishing (CMP) process that removes a hardmask. 
   It should be recognized that certain dielectric materials (e.g., layers  106 ,  122  in FIG.  1 A)(e.g., CVD SiO x  or TEOS) that may not require the above-described special processing may be used. However, these materials also present a higher dielectric constant, and thus are not the most desirable of materials. Other more desirable dielectric materials, other than SiCOH, include spin-on dielectrics such as methyl silsesquoixane (MSQ) available from JSR Corp., hydrogen silsesquoixane (HSQ)™ available from Dow Corning, or chemical vapor deposited (CVD) SiCOH materials, SiLK™ from Dow Chemical or porous SiLK™. 
   In the case that the  FIG. 2  embodiment is to be constructed, the opening forming step may include interconnecting at least two of the first connector head areas  154 A,  154 B, and/or interconnecting at least two of second connector head areas  158 A,  158 B. 
   Returning to  FIG. 1A  in conjunction with  FIG. 6 , as indicated above, one feature of the invention is that interlayer connectors  100 A,  100 B eliminate the need for white space fill above and below conventional via fill because connectors  100 A,  100 B are coplanar with the on device wiring  132 A,  132 B. That is, as shown in  FIG. 6 , openings  150 A,  150 B can either land on device areas with no wires below or partially on wires below, which provides a number of options in forming interlayer connectors  100 A,  100 B. For example, a main body  152 B ( FIG. 6 ) may be partially landed on a wire  132 B in first distal layer  106 . In this case, first connector head area  154 B is formed from a non-landed part of main body  152 B. Where wire  132 B is a current-carrying wire, an interlayer connector  100 B formed from opening  150 B may partly form a contact via when a metal is deposited in opening  150 B, and partly form an irremovable connector. That is, interlayer connector  100 B prevents delamination and may also acts as a contact via to a current-carrying wire  132 B. In this case, second connector head  120  is also an active current-carrying wire. Alternatively, where wire  132 B is not a current-carrying wire (i.e., a dummy wire), interlayer connector  100 B may simply provide an irremovable connector formed either by depositing a dielectric or a metal. In the later case, the metal is preferably of the same makeup as wire  132 B. In embodiments where wire  132 B is a dummy wire, second connector head  120  may be any shape (e.g., a bolt or a bar shape) that is larger than the diameter of connector body  110 . Where no wire is located below a main body  152 A, first connector head area  154 A may be formed anywhere about the bottom of main body  152 A. In this case, second connector head  120  is inactive, but may be sized to provide any necessary amount of fill. Fill material for opening  150 A may be dielectric or metal. 
   With continuing reference to  FIGS. 1A and 6 , it should be recognized that while particular embodiment for forming openings  150 A,  150 B have been described above, they may be formed using a dual damascene wiring using any known method, with the additional placement of interlayer connector openings in the via masks where they will fit. Alternatively, openings  150 A,  150 B may be provided with any single damascene process for vias only, i.e., without formation of opening  150 C. The opening forming step may be provided as part of forming contact via  112  (FIG.  1 )(from opening  150 C) or fill structures (not shown), e.g., wire fill or conventional via fill. The number of openings  150 A,  150 B that ultimately form connectors  100 A,  100 B can be user defined based, for example, on the amount of available space, the amount of delamination protection desired, etc. 
   Turning to  FIG. 7 , a second step of the method includes filling each opening  150 A,  150 B to form an interlayer connector  100 A,  100 B. This step may include depositing a metal or a dielectric  180  including any necessary liner materials (not shown). In terms of the former, the metal may be any desired metal where opening  150 A does not land on a wire  132 . If the opening  150 B partially lands on an opening, then the metal is preferably the same makeup as the wire  132 . Where the wire is copper, conventional liner material (e.g., one or more of TaN, WN, TiN, RuN, TaSiN, etc.), seed material (preferably Cu or Al) and copper (Cu) plating depositions may be conducted. Note that a conformal liner process, preferably chemical vapor deposition (CVD) or physical vapor deposition (PVD) with good step coverage in overhang structures is preferred, but not required. Optional CVD Cu deposition for seed, plating, or both could be employed to maximize metal fill of opening  150 B bottoms. A dielectric material may be used where interlayer connector  100 A does not to also function as a contact via. In terms of dielectric liner material, the material may include any dielectric having sufficient strength to withstand the expected delaminating stresses, such as silicon dioxide (SiO 2 ) deposited using a conformal plasma enhance CVD (PECVD), sub-atmospheric CVD (SCVD), atmospheric CVD (ACVD), thermal CVD (THCVD) or a spin-on process. Subsequent processing, as shown in  FIG. 8 , may include customary finishing steps such as chemical mechanical polishing (CMP), reactive ion etching (RIE) or wet etchback, or a combination of above, to remove the excess liner, metal, dielectric, etc., from the wafer surface. 
     FIG. 9  illustrates application of the present invention across a plurality of wiring levels of a semiconductor device. In  FIG. 9 , current-carrying wires are indicated in black, and dummy wiring is indicated in gray. It should be recognized that main bodies  110  and connector heads  102 , although shown as separate parts, are actually integrally formed. 
   While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.