Abstract:
A method of forming an HDP CVD oxide layer over a metal line structure, comprising the following steps. A semiconductor structure having metal lines formed thereon to form a metal line structure is provided. The metal lines having exposed sidewalls. The metal line structure is treated with N 2 O to form a layer of Al 2 O 3  on each of the metal line exposed sidewalls to form a N 2 O treated metal line structure. An HDP CVD oxide layer is formed over the N 2 O treated metal line structure to form a resulting metal line structure. Whereby the resulting metal line structure is free of metal voids.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to the use of high density plasma (HDP) chemical vapor deposition (CVD) oxide as intermetal dielectric layers (IMD), and specifically to the use of HDP CVD IMD oxide layers for high aspect ratio design rule for 0.25 to 0.15 μm technology. 
     BACKGROUND OF THE INVENTION 
     High density plasma (HDP) chemical vapor deposition (CVD) oxide has been used as an intermetal dielectric layer (IMD) and passivation materials due to its good gap filling capability. This holds true even for HDP fluorinated silica glass (FSG). 
     HDP CVD combines sputtering and depositing processes. The gap fill capability is influenced under the sputtering action: seams are found under a low sputter; and metal clipping is found under a high sputter. 
     However, in devices with high aspect ratio design rule for 0.25 to −0.15 μm technology, metal voids were observed in metal lines over which the HDP CVD oxide IMD or passivation layers were formed. Such metal voids cause not only metal line off and serious metal electron migration, but also reliability failures. 
     U.S. Pat. No. 6.030,881 to Papasouliotis et al. describes forming an HDP CVD layer over an aluminum (Al) line. 
     U.S. Pat. No. 6,008,120 to Lee describes a process for forming an FSG layer over an Al line. 
     U.S. Pat. No. 5,872,058 to Van Cleemput et al. describes forming an HDP CVD layer over an Al line. 
     U.S. Pat. No. 6,035,803 to Robles et al. describes a fluorinated carbon film process. 
     U.S. Pat. No. 5,759,635 to Logan describes a fluorocarbon polymer PECVD process for a low-k layer. 
     The article “A Mechanism of Stress-induced Metal Void in narrow Aluminum-based Metallization with the HDP CVD oxide dielectric,” Soo Geun Lee et al., IEEE, Jun., 1999, pp. 99-149 to 99-151, proposes a mechanism by which metal voids form when an HDP CVD oxide IMD layer is formed over aluminum (Al) metal lines in devices with 0.25 μm rule. Factors affecting formation of metal voids were: (1) the deposition temperature of the HDP CVD oxide; (2) the metal layer structure; and (3) the line width. Decreasing the deposition temperature of the HDP CVD oxide reduced formation of the metal voids but occurred slightly at metal pitches lower than 0.75 μm. When TiN replaced Ti in glue and capping layers for Al metal lines, no metal voids were observed. 
     From the experimental results, it is suggested that the hydrostatic stress due to the reaction between the Ti and Al at the high temperature HDP CVD oxide deposition is the major driving force for metal void formation. Probability of metal void formation increases rapidly with the HDP CVD oxide formation temperature due to higher induced stress and faster diffusion at higher temperatures. 
     Annealing at 450° C. for 30 minutes after metal patterning eliminated void formation at 0.7 μm and 0.64 μm pitch metal lines. Also, when the backside helium (He) pressure was increased from the normal condition of 4.5 Torr inner/9 Torr outer to 7.0 Torr inner/10.0 Torr outer, the density of void formation was slightly reduced. At 0.8 μm pitch of metal pattern, no metal void was observed at RF bias power of 2000 W and 1600 W. However, when the metal pitches were decreased to 0.7 μm and 0.64 μm, metal voids formed at this lower RF bias power. 
     The article “Cu Behaviors Induced by Aging and Their Effects on Electromigration Resistance on Al-Cu Lines,” Takeshi Nogami et al., American Institute of Physics, 1996, pp. 198-213 describes an experimental procedure whereby annealed films were subjected a 250° C. aging treatment, to enhance thermal diffusion of Cu atoms in the grains, and studied to determine the role of segregated Cu atoms at grain boundaries. The role of the preferential diffusion of Cu was studied through comparison of time-to-failure&#39;s (TTF&#39;s) between treated AlSiCu and AlSi lines. A new model was proposed for understanding the electromagnetic (EM) resistance improvement by adding Cu atoms and the aging treatment that includes the role of the preferential diffusion of Cu atoms along the grain boundary and the role of the segregated Cu atoms. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a method of eliminating voids in metal lines. 
     Another object of the present invention to provide a method of eliminating voids in aluminum based metal lines down to 0.25 μm design rule technology. 
     Yet another object of the present invention is to provide a method of eliminating voids in aluminum based metal lines down to 0.15 μm design rule technology. 
     Other objects will appear hereinafter. 
     It has now been discovered that the above and other objects of the present invention may be accomplished in the following manner. Specifically, a semiconductor structure having metal lines formed thereon to form a metal line structure is provided. The metal lines having exposed sidewalls. The metal line structure is treated with N 2 O to form a layer of Al 2 O 3  on each of the metal line exposed sidewalls to form a N 2 O treated metal line structure. An HDP CVD oxide layer is formed over the N 2 O treated metal line structure to form a resulting metal line structure. Whereby the resulting metal line structure is free of metal voids. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features and advantages of the method of the present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which like reference numerals designate similar or corresponding elements, regions and portions and in which: 
     FIGS. 1 to  3  schematically illustrates in cross-sectional representation a preferred embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Unless otherwise specified, all structures, layers, steps, etc. may be formed or accomplished by conventional methods known in the prior art. 
     Problem Known to the Inventors 
     In devices with high aspect ratios design rule for 0.25 to 0.15 μm technology, metal voids were observed in the metal lines with high density plasma (HDP) chemical vapor deposition (CVD) of intermetal dielectric (IMD) and passivation material. The process conditions related to the formation of metal voids were studied. This problem known to the inventors is not prior art. 
     When titanium nitride (TiN) was used as the glue layer under the aluminum metal lines and also as the overlying capping layer, or anti-reflective coating (ARC), various degrees of metal voids were observed even with the same pattern ratios, but different aspect ratios, under AMAT HDP and Novellus HDP. Specifically, as the metal pitch decreased below 0.8 μm design rule, metal voids were observed at narrow metal lines and were more serious for high aspect ratios under the same pitch condition. The defects appeared not only at the top and side of the Al metal line, but also at the bottom of the metal lines near the boundary between the TiN glue layer and the overlying Al metal line. 
     The formation of metal voids at various process conditions were studied to propose the mechanism of the stress induced metal voids. Two types of HDP equipment were used for the metal void study. One was the AMAT HDP tool and the other was the Novellus HDP tool. Based on the possible factors, experiments were performed to identify mechanisms and to design a process integration to solve the problem of metal void formation. 
     From these experiments, several factors were found to influence metal void formation such as HDP deposition temperature, film stress, metal film roughness, and metal density. A new integration process and scheme, subject of the present invention, has been developed to effectively solve the metal void issue that is not only successful for 0.25 μm technology, but also for advanced 0.15 μm technology. 
     Preferred Embodiment of the Present Invention 
     Accordingly as shown in FIG. 1 starting semiconductor structure  10  includes upper oxide (SiO 2 ) layer  12 . Semiconductor structure  10  is also understood to possibly include a semiconductor wafer or substrate, active and passive devices formed within the wafer, conductive layers and dielectric layers (e.g., inter-poly oxide (IPO), intermetal dielectric (IMD), etc.) formed over the wafer surface. The term “semiconductor structure” is meant to include devices formed within a semiconductor wafer and the layers overlying the wafer. 
     Metal lines  14 ,  16  are formed over oxide layer  12  by conventional methods. Metal lines  14 ,  16  may be formed of Al, an AlSiCu alloy, or an AlCu alloy, and are preferably comprised of an aluminum copper alloy (AlCu) containing 0.5% by weight copper. 
     Metal lines  14 ,  16  are electrically connected to various devices (not shown) formed within/on semiconductor structure  10  as is known in the art and permits electrically interconnection between such devices and/or with such devices and other electrical connections external to a semiconductor integrated circuit (IC) chip within which semiconductor structure  10  and such devices are incorporated. 
     Metal lines  14 ,  16  have exposed sidewalls  24 . 
     Metal lines  14 ,  16  have a pitch P from about 0.15 up to and over 1.6 μm, and have an aspect ratio (H/W) of from about 2.0 to 4.0, and more preferably about 3.0. 
     Metal lines  14 ,  16  have glue layers/under layers  18 , respectively, formed between them and oxide layer  12  which serve to bind AlCu lines  14 ,  16  to oxide layer  12 . Glue layers  18  may be formed of (thin Ti deposition before TiN formation), and are preferably comprised of titanium rich titanium nitride (Ti rich TiN). TiN. Glue layers  18  are involved two layers, Ti rich thin layer from about 130 to 170 Å thick, and are preferably about 150 Å thick. 
     Overlying metal lines  14 ,  16  are anti-reflective coating (ARC) layers  20 . ARC layers  20  may be formed of Ti, TiN, or Ti rich TiN, and are preferably comprised of titanium nitride (TiN). TiN ARC layers are from about 500 to 600 Å thick, and are preferably about 550 Å thick. 
     Prior methods to eliminate/minimize void formation within metal lines  14 ,  16  during HDP CVD oxide formation over metal lines  14 ,  16  to form an IMD layer or a passivation layer  30 , for example, have only been able to do so for down to 0.7 to 0.64 μm pitch/design rule of the metal lines  14 ,  16 . 
     The inventors have determined that metal density of the wafers upon which metal voids are formed by the HDP CVD oxide IMD or passivation layer  30  deposition that lead to metal line abnormalities and serious electromigration (EM) is dividable into two groups: those having a metal density above about 35%; and those having a metal density below about 35%. Metal density is determined by the total amount of surface area of the wafer upon which metal, or metal structures/devices/lines  14 ,  16  have been formed. For example a blank wafer has a 0% metal density and a wafer totally covered in metal has a metal density of 100%. 
     Brief Summary of the Invention 
     The method of the present invention includes treating metal lines  14 ,  16  with a N 2 O treatment (see FIG. 2) before the HDP process (see FIG. 3) using either the AMAT or Novellus tools, for example, under high aspect ratio and with either high (greater than 35% (&gt;35%)) or low (less than 35% (&lt;35%)) metal density. 
     Experimental Results 
     Various experiments were conducted using the AMAT and Novellus HDP tools, respectively, as noted in the tables below. Note that “X” means failure, i.e. metal voids were formed after HDP CVD oxide IMD or passivation layer formation, and “O” means metal voids were not detected. 
     Table I 
     General experiments were conducted with the AMAT and Novellus HDP tools to gauge the degree of metal void formation under the same pattern density, but with different metal thickness and pitches. These experiments were conducted at the following conditions, with the results summarized in TABLE I below: 
     metal density—greater than 35%; 
     bias RF power—about 2800 W; 
     metal line composition—AlCu(0.5% wt.) alloy; 
     He back pressure (inner He/outer He)—2.5 Torr/9.0 Torr; and 
     BKM recipe. 
     
       
         
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE I 
               
               
                   
               
               
                   
                 Pitch 
                   
                   
                   
                   
                   
                   
                   
               
               
                 Thick- 
                 (μm) 
               
               
                 ness 
                 → 
               
               
                 (Å) 
                 0.6 
                 0.7 
                 0.8 
                 0.9 
                 1.0 
                 1.2 
                 1.4 
                 1.6 
               
               
                   
               
             
             
               
                 4K 
                 O 
                 O 
                 O 
                 O 
                 O 
                 O 
                 O 
                 O 
               
               
                 6K 
                 X 
                 X 
                 X 
                 X 
                 X 
                 O 
                 O 
                 O 
               
               
                 8K 
                 X 
                 X 
                 X 
                 X 
                 X 
                 X 
                 O 
                 O 
               
               
                 9K 
                 X 
                 X 
                 X 
                 X 
                 X 
                 X 
                 X 
                 O 
               
               
                   
               
             
          
         
       
     
     As shown in TABLE I above, metal void problems worsen with increased metal line  14 ,  16  thickness and increased aspect ratio. The higher the aspect ratio, the more serious the metal void formation. 
     Table II 
     Further experiments were then conducted under different conditions, i.e. reducing the bias RF power from 2800 W to 2400 W, and increasing the He back pressure (inner He/outer He) from 4.5 Torr/9.0 Torr (normal flow recipe) to 7 Torr/9.5 Torr (high flow recipe). The results are summarized in TABLE II below at the following conditions: 
     metal density—greater than 35%; 
     metal line composition—AlCu (0.5% wt.) alloy; 
     bias RF power—AMAT HDP tool: about 2400 W; Novellus HDP tool: less than 2500 W 
     line  14 ,  16  thickness—about 9,000 Å; 
     He back pressure—AMAT tool: about 7 Torr/9.5 Torr; Novellus tool: greater than about 9 Torr; and 
     BKM recipe. 
     
       
         
               
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE II 
               
               
                   
                   
               
               
                   
                 Pitch 
                   
                   
                   
                   
                   
                   
               
               
                   
                 (μm) 
                 0.8 
                 0.9 
                 1.0 
                 1.2 
                 1.4 
                 1.6 
               
               
                   
                   
               
             
             
               
                   
                 AMAT 
                 X 
                 X 
                 X 
                 X 
                 O 
                 O 
               
               
                   
                 HDP tool 
               
               
                   
                 Novellus 
                 O 
                 O 
                 O 
                 O 
                 O 
                 O 
               
               
                   
                 HDP tool 
               
               
                   
                   
               
             
          
         
       
     
     As shown in TABLE II above, even with a low bias RF power, metal voids are still an issue when using the AMAT HDP tool at a high metal density (i.e. with a metal density greater than 35%). 
     Table III 
     In attempts to remedy the undesirable results for the Novellus HDP tool summarized in TABLE II, experiments were then conducted with only the Novellus HDP tool and at a metal density of less than 35%. The results are summarized in TABLE III below at the following conditions: 
     metal density—less than 35%; 
     metal line composition—AlCu(0.5% wt.) alloy; 
     bias RF power—less than 2500 W; 
     line  14 ,  16  thickness—about 9,000 Å; 
     He back pressure—greater than about 9 Torr; and 
     BKM recipe. 
     
       
         
               
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE III 
               
               
                   
                   
               
               
                   
                 Pitch 
                   
                   
                   
                   
                   
                   
               
               
                   
                 (μm) 
                 0.8 
                 0.9 
                 1.0 
                 1.2 
                 1.4 
                 1.6 
               
               
                   
                   
               
             
             
               
                   
                 Novellus 
                 X 
                 X 
                 X 
                 X 
                 X 
                 X 
               
               
                   
                 HDP tool 
               
               
                   
                   
               
             
          
         
       
     
     As shown in TABLE III above, even after changing to a low metal density (i.e. with a metal density less than 35%), metal void formation was still a problem at all pitches tested when using the Novellus HDP tool at a low bias RF power and a high flow recipe (greater than about 9 Torr). This shows that for a metal density less than  35 %, the metal void issue can not be resolved due to the loading effect of sputtering. 
     Key Step of the Invention 
     As shown in FIG. 2, in a key step of the present invention, the inventors have discovered that first pre-treating the metallized structure of FIG. 1 with an N 2 O treatment  22  before the HDP process using the AMAT or Novellus tools, for example, with BKM recipes to form HDP CVD oxide IMD or passivation layer  30  can be used to solve the metal void problem under a high aspect ratio and with high or low metal density (i.e. greater than 35% or less than 35%, respectively). (The tools may include an N 2 O gas line.) Specifically, a N 2 O flow of from about 800 to 1600 sccm, and more preferably from about 1400 sccm is applied (as at  22 ) to the structure of FIG. 1 for from about 40 to 90 seconds, and more preferably 45 seconds, with an RF bias of from about 180 to 220 W, and more preferably about 200 W, at a temperature from about 360 to 440° C., and more preferably from about 380 to 400° C., using an AMAT P5000 chamber, Centura D XZ  chamber, or Novellus chamber tool. The N 2 O pre treatment may be performed in the same chamber/with the same tool as the AMAT or Novellus tools. 
     This forms layers  26  of aluminum oxide (Al 2 O) on the exposed sidewalls  24  of AlCu metal lines  14 ,  16 , respectively. Al 2 O layers  26  are from about 50 to 300 Å thick, and are more preferably about 150 Å thick. 
     That is: 
     
       
         3N 2 O+2Al→3N 2 +Al 2 O 3   
       
     
     where, it is believed: 
     Al 
     
       
         3N≡N—O+→3N≡N+Al 2 O 3   
       
     
     Al 
     It is believed the formation of Al 2 O 3  layers  26  prevents formation of metal voids during formation of HDP CVD oxide IMD/passivation layer  30  over metal lines  14 ,  16  because of the thermal stress difference between Al 2 O 3  and AlCu. 
     Thus, the N 2 O pre-treatment  22  is performed at the following conditions: 
     N 2 O flow—from about 800 to 1600 sccm, and more preferably from about 1000 to 1400 sccm; 
     time—from about 40 to 90 seconds, and more preferably about 45 seconds; 
     bias RF power—less than 200 W; 
     temperature—from about 360 to 440° C., and more preferably from about 380 to 400° C.; 
     to form Al 2 O 3  layer  26  on the exposed sidewalls  24  of AlCu lines  14 ,  16  having a thickness from about 50 to 300 Å, and more preferably about 150 Å. 
     The AMAT HDP and Novellus HDP tools were modified to allow for the N 2 O treatment of the present invention by adding an N 2 O gas line to introduce the N 2 O to the metallized wafer before the actual HDP process in forming the HDP CVD oxide IMD or passivation layer  30 . That is the process recipe for the PECVD was designed with an N 2 O gas line (involved the PEOX, PETEOS). The N 2 O gas line can go into the respective tool chamber form injector. 
     For example, after an N 2 O pre-treatment in accordance with the present invention for 45 seconds with an RF bias of 200 W, a temperature of about 400° C., and an N 2 O flow of about 1400 sccm, experiments were conducted using an AMAT HDP and a Novellus HDP tool to determine metal void formation. These experiments were conducted at the following conditions, with the results summarized in TABLE IV below: 
     metal density—greater than 35% or less than 35% 
     bias RF power—about 2800 W; 
     metal line composition—AlCu(0.5% wt.) alloy; 
     line  14 ,  16  thickness—about 9,000 Å; 
     He back pressure—AMAT tool: about 7 Torr/9.5 Torr; Novellus tool: greater than about 9 Torr; and 
     BKM recipe. 
     
       
         
               
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE IV 
               
               
                   
                   
               
               
                   
                 Pitch 
                   
                   
                   
                   
                   
                   
               
               
                   
                 (μm) 
                 0.8 
                 0.9 
                 1.0 
                 1.2 
                 1.4 
                 1.6 
               
               
                   
                   
               
             
             
               
                   
                 AMAT 
                 O 
                 O 
                 O 
                 O 
                 O 
                 O 
               
               
                   
                 HDP tool 
               
               
                   
                 Novellus 
                 O 
                 O 
                 O 
                 O 
                 O 
                 O 
               
               
                   
                 tool 
               
               
                   
                   
               
             
          
         
       
     
     As shown in TABLE IV above, all products passed with no detectable metal voids being formed. 
     SUMMARY OF THE INVENTION 
     The AlCu(0.5% wt.) metal line structure of FIG. 1 is subjected to the N 2 O pre-treatment of the present invention as noted above. 
     As shown in FIG. 2, the N 2 O pre-treatment  22  forms Al 2 O 3  layers  26  on exposed sidewalls  24  of AlCu metal lines  14 ,  16 . 
     Thus, when HDP CVD oxide IMD/passivation layer  30  is formed over AlCu metal lines  14 ,  16 , metal voids are not formed, even for 0.25 μm down t 0.15 μm technology metal lines  14 ,  16 . 
     While particular embodiments of the present invention have been illustrated and described, it is not intended to limit the invention, except as defined by the following claims.