Dual layer positive photoresist process and devices

A method of fabricating a semiconductor device including the steps of forming a first layer of positive photoresist on a substrate surface; exposing selected portions of the photoresist; developing the photoresist to remove those portions which are exposed and leave those portions which are not. Then, plasma etching the substrate and the unexposed resist so that the etch fixes the photoresist. Subsequently forming a second layer of photoresist over the fixed first layer and over the etched substrate. Finally, exposing and developing selected portions of the second layer of photoresist in a pattern which is noncongruent with fixed first photoresist layer. This forms a selective double photoresist layer with the second layer over the fixed first layer, and may also provide single layers of either the first or second photoresist.

BACKGROUND OF THE INVENTION 
I. Field of the Invention 
The invention relates generally to semiconductor integrated circuits and 
processes for their manufacture, and more particularly to an intermediate 
integrated circuit, having a dual layer positive photoresist, and a dual 
layer positive photoresist process for the manufacture of integrated 
circuits. 
II. Descrpition of the Prior Art 
In the manufacture of integrated circuits, it is well known to use a photo 
lithographic technique to form an image or pattern in a photoresist 
emulsion on the semiconductor substrate. The pattern then serves as a mask 
for subsequent etching of the underlying substrate, or for the 
introduction of dopants into the underlying substrate. The substrate is 
covered with a layer of photographic emulsion called photoresist and light 
or other radiation is applied to selected portions of the emulsion. This 
causes a selective polymerization of the resist. The unpolymerized resist 
is then developed or dissolved and removed. This leaves a pattern on the 
surface of the substrate of openings or windows in the photoresist layer. 
There are two types of photoresist, negative and positive. A negative 
resist or light hardening resist is one in which light from the exposure 
process hardens or polymerizes the photoresist. A postive photoresist, or 
light softened resist, is one in which the light from the exposure process 
softens or depolymerizes the photoresist. This process, and its place in 
the overall manufacture of integrated circuits, is known and those who 
wish more information are referred to the textbooks and articles in the 
field, for example, Raymond M. Warner, Integrated Circuits (New York: 
McGraw-Hill, 1965), pp. 150 and 151 in particular. And Peter E. Gise, 
Semiconductor and Integrated Circuit Fabrication Techniques (Rustern, 
Virginia: Prentice-Hall, 1970), pp. 104-109. The Warner text describes 
only negative photoresist, while Gise describes negative and positive. 
Both books describe also the step of photoresist and photo lithography in 
the overall manufacture of integrated circuits. Multiple masking and 
several photo lithographic steps are used in the manufacture of modern 
integrated circuits. 
The present invention relates to the use of positive photoresist. In 
certain process steps, it is desirable to have a double layer of 
photoresist over portions of the substrate, and a second layer of 
photoresist over part of the first layer, but not all of the first layer 
of photoresist. An example is in the manufacture of programmable roms, it 
is necessary to provide additional protection during an ion field implant 
for nitride lines on the substrate. For example, it is desirable to 
implant with energy of 90 KEV, which is possible with a dual layer 
photoresist, while with a single layer resist only approximately 35 KEV 
may be used. The difficulty in using positive photoresist is that the 
portions of the first layer, which remain and are covered by the second 
positive photoresist layer and which are exposed to light in the second 
photo lithographic technique, are subject to being removed by a softened 
and depolymerized during the exposure of the second photoresist. Further, 
the portions of the first photoresist layer remaining during the second 
photoresist may be subject to being dissolved, wrinkled due to heat, lose 
their dimensional and chemical integrity. 
An object of the present invention is to provide a dual layer positive 
photoresist process in which two layers of positive photoresist may be 
used one at least partially over the other. Also an object of the 
invention is intermediate semiconductive device that includes at least two 
layers of positive photoresist on the substrate with other parts having 
only the first layer of positive photoresist on the substrate. 
Another object of the invention is to provide a repeatable dual layer 
photoresist process employing positive photoresist that may be used in an 
industrial setting with commercial acceptable reproducibility and high 
yield. 
A further object of the invention is to provide a dual layer positive 
photoresist in which the first resist retains its integrity until after 
the second photoresist layer has been applied and then all the processing 
steps that are needed are performed until both photoresists are stripped; 
and in which the second positive photoresist may be satisfactorily applied 
and used until it has all been removed. 
SUMMARY OF THE INVENTION 
According to one aspect of the invention, there is provided a method of 
fabricating a semiconductor device. It includes the steps of forming a 
first layer of positive photoresist on a substrate surface; exposing 
selected portions of said photoresist layer; developing said layer to 
remove those portions which were exposed and leaving other portions which 
were not exposed; plasma etching said substrate and said resist so that 
the plasma etch fixes the remaining photoresist; forming a second layer of 
photoresist over the fixed first layer and over the etched substrate; then 
finally, exposing and developing selected portions of the second layer of 
photoresist in a pattern non-congruent with the fixed first photoresist 
layer, thus forming a double photoresist layer with the second layer over 
the fixed first layer. 
According to another aspect of the invention, there is provided an 
intermediate semiconductor device having a substrate and a first mask of a 
fixed positive photoresist over selected portions of substrate.

DETAILED DESCRIPTION OF THE INVENTION 
In FIG. 1 there is a shown a substrate I and a layer of positive 
photoresist II, a portion of which is being exposed to light or radiation 
shown with legend III. The substrate I has a silicon body X, with a layer 
of silicon dioxide XII which, in turn, has a layer of silicon nitride XIV 
thereon. The positive photoresist II is next to the silicon nitride layer 
XIV. FIG. 1, as well as all figures in the drawings, are not to scale. The 
SiO2 layer XII is, for example, 700 angstroms thick, the Si3N4 layer XIV 
is 1200 angstroms thick, and the positive photoresist II is about 12,000 
angstroms thick. 
Since the photoresist II is positive, the light III from the exposure 
process softens or depolymerizes the photoresist in those regions where 
the light impinges on the photoresist. The wafer is then developed and the 
softened or depolymerized resist is removed. This is shown in FIG. 2. 
The wafer is then subjected to a plasma etch, the results of which are 
shown in FIG. 3. The etch with the remaining resist II as a mask, etches, 
i.e., removes, the exposed portion of the Si3N4 layer XIV and SiO2 layer 
XII. More importantly, in the present invention, the plasma fixes the 
unexposed resist II in FIG. 3 and renders the resist impervious to further 
exposure to light and solvents, and to some extent high temperature. It is 
believed that a "skin" is formed on the outer surface of the resist II in 
FIG. 3. It renders the resist impervious to further exposure in solvents 
and also allows it to be baked at 50.degree. to 100.degree. C. higher than 
its normal flow point, which is approximately 90.degree. C. 
As shown in FIG. 4, the next step is to apply a second layer of positive 
photoresist XX. It covers the remaining portion of the first layer of 
photoresist II. This second layer of positive photoresist is then exposed 
to light, for example that portion of the wafer which is to the left in 
FIG. 2 of point a is exposed, and the portion on the wafer to the right of 
the point a in FIG. 4 is not exposed. Since this is positive photoresist, 
light from the exposure softens or depolymerizes the photoresist to the 
left of point a. 
As shown in FIG. 5, the exposed photoresist is then developed which 
dissolves the exposed depolymerized or softened photoresist. This leaves 
the device shown in part in FIG. 5. In FIG. 5 there is shown body X, and 
to the right a layer of silicon dioxide XII, an overlayer of silicon 
nitride XIV, a first photoresist layer II, and an overlying layer of 
second photoresist XX, which extends beyond the first photo layer II onto 
the etched substrate in contact with the body X. 
In FIG. 5, to the left there is shown the body X, with the overlying layer 
of silicon dioxide XII, silicon nitride XIV, and the first photoresist II 
which has been fixed during a prior step and thus was not attacked or 
removed during the second photoresist application exposure or development. 
In typical application, the step after what is shown in FIG. 5 is to 
implant, for example, boron in a field implant using a high energy, for 
example 90 KEV. The double photoresist layer to the right in FIG. 5 is 
sufficient to protect the underlying silicon nitride lines from the 
implant. 
A first preferred embodiment of carrying out the process of the invention 
may be described in detail as follows. One begins with wafers having 1200 
angstroms of Si3N4 over 750 angstroms of SiO2. 
The wafers are first baked at 200.degree. C. for thirty minutes to dry them 
and prepare them for coating with the first photoresist. 
A coat of 100% each MDS is spun dry at 3200 RPMs. HMDS increases the 
adherence of the photoresist to the silicon nitride layer. 
There is then coated a photoresist commercially known as AZ 111S, and it is 
spin coated at 3200 RPMs. 
The photoresist is then baked for 15 minutes at 95.degree. C. 
A first mask then exposes selected portions of the photoresist. A Perkin 
Elmer projection aligner type 221 was used. This step corresponds to FIG. 
1 of the drawing. 
The exposed photoresist is then developed in a commercial type AZ 311 
developer, 2:3, distilled water at 22.degree. C. This is followed by a 
bake at 85.degree. C. for 20 minutes. The device now appears as shown in 
FIG. 2. 
A plasma etch is then carried out, preferably in a Planar etcher. A Branson 
sigma etcher was used for 30 seconds at 3.6 TORR, 300 watts, using a 
plasma of 5 SCCM of O2, 450 SCCM of CF4, and 30 SCCM CCLF3. 
The etched step is important in two respects. First, it fixes the 
photoresist so the photoresist is hardened. This makes the fixed 
photoresist neither photosensitive to further light, nor dissolvable by 
the usual solvents which are used in the subsequent steps. There is an 
additional feature in that the fixing allows the wafer to be baked in 
subsequent steps at 50.degree. to 100.degree. C. higher than the normal 
flow point of the unfixed photoresist. The unfixed normal flow point is 
about 90.degree. C. 
The plasma exposure generates, it is believed, a chemical change in the 
photoresist and specifically the outer layer or "skin" which controls the 
resist left unexposed in the first layer. 
The plasma is what fixes the first layer, and experimentation has indicated 
that it is energy-sensitive. A minimum of 6 watts/CM2 have been found 
satisfactory. In a commercial plasma etcher with 300 watts at 3.6 TORR, 
the skin is fixed in about one second. 
In the example shown in FIG. 3, the etch is continued for thirty seconds. 
This is to etch the substrate and particularly through the Si3N4 layer XIV 
and SiO2 layer XII, which is not covered by the resist II. The mask II in 
FIG. 3 retained its integrity during the etching. 
The wafer is then baked at 150.degree. C. for 35 minutes We noted that this 
temperature is above the normal flow point, approximately 90.degree. C., 
of the unfixed photoresist. 
The wafer is then coated with 100% HMDS spun dry at 3200 RPMs. This 
performs the same function as in the previous steps where to provide 
better adhesion between the second photoresist layer and the underlying 
unetched substrate. 
The surface is then coated with a second positive photoresist AZ 111S spun 
at 3200 RPMs. This is as shown in FIG. 4. 
There is then a baked step at 95.degree. C. for 15 minutes. This is 
followed by an exposure step. Again a Perkin Elmer 221 printer used. The 
exposed positive photoresist was then developed using AZ311 developer 2:3 
distilled H2O 22.degree. C. The developed wafer is shown in FIG. 5. 
A baked step at 85.degree. C. for 20 minutes followed. After which there 
was a boron implant at 90 Kev. The goal here is to provide additional 
protection during this field implant for silicon nitride lines. This 
allowed the use of higher energy, e.g., 90 Kev, versus 35 Kev as will be 
used without the double photoresist layer. The ion implantation of this 
type is used to produce a number of circuits which require raising the 
background dopent level and to short out various transistors which may 
exist in the body of the silicon that have been put there previously. An 
example is in programmable rom production. This will also provide a deeper 
implantation, for example with a higher background voltage for a field 
layer. n-channel MOS transistors can have higher voltages with the field 
implantation. Further, high voltage field implantations may be used to 
avoid transistor effect between the edges and the drain connections of the 
MOS. An example of higher voltage MOS is in the 30 to 35 volt range. While 
these are examples of the use of a double photoresist to permit higher 
field implantations, it will be appreciated that the present invention is 
a general technique which will find many applications in many different 
devices. 
The feature of being able to make the fixed first photoresist layer at a 
higher temperature is important in several respects. The higher 
temperature bakes following the fixing of the first photoresist layer 
permits the removal of water from the surface more efficiently, and this, 
in turn, increases the adhesion of the photoresist that is subsequently 
applied and thus prevents peeling of the photoresist. 
Other examples where high temperature bakes are needed and with the fixing 
of the photoresist will find application include wet oxide etching, dry 
aluminum etching, or wet aluminum etching. 
Results of the process have been favorable. The original mask II retained 
its integrity, although it became slightly wrinkled from the 140.degree. 
bake. There was no loss of resist dimensions over the nitride lines, and 
the total loss of resist thickness was less than 3000 angstroms. The 
second mask dimensions were center of specification, and there was no 
evidence of lifting or peeling in those areas where the second mask XX 
overlapped the first mask II. 
After the implantation step, the photoresists, II and XX, are stripped. 
This is done in 15 minutes ultrasonic acetone, 5 minutes DMF 90.degree. 
C., and 10 minutes 1:1 sulfuric: nitric acids and 150.degree. C. 
A second example of the process of the invention is set forth below. The 
different steps are listed in turn. EXAMPLE 
Bake: 200.degree. C. 30 minutes 
Coat: 100% HMDS 2000 RPM dry 
Coat: KTI 809 32% solids 3500 RPM Tres.=1.2 m 
Bake: 90.degree. C. 30 minutes 
Expose: Kasper contact aligner 25002 mask2 12 secs. 
Develop: KTI 809 developer 1:1 DI water 22.degree. C. 
Bake: 90.degree. 30 minutes 
Plasma: LFE - 302 barrel etcher with cage 
Descum: 3.0 minutes 7.0 Torr 100 watts 100% O.sub.2 
Etch: 2.5 minutes 2.0 Torr 100 watts 92% Cf.sub.4 8% O.sub.2 
Bake: 150.degree. C. 45 minutes 
Coat: 100% HMDS 2000 RPM dry. 
Coat KTI 809 32% solids 3500 RPM Tres=1.2 m 
Bake: 90.degree. 30 minutes 
Expose: Kasper contact printer 25002 mask 21 14 seconds 
Develop: KTI 809 developer 1:1 DI water 22.degree. C. 
Descum: LFE 302 barrel etcher without cage 3.0 minutes 7.0 Torr 100 watts 
100% O.sub.2 
Bake: 90.degree. C. 15 minutes 
Implant: Boron 90 Kev 
Strip: 15 minutes ultrasonic acetone 
5 minutes DMF 90.degree. C. 
10 minutes 1:1 sulfuric--nitric 150.degree. C. 
Some of the differences between the first example and the second example 
should be noted. The two different photoresists are both commercially 
available ones, and any convenient or conventional commercial photoresist 
may be used. In the exposing step, any convenient or conventional aligner 
may be used. In the plasma etching step, as noted above, it is preferable 
that the etching be with a uniform energy per unit surface area. A Planar 
etcher (first example) is better than a Barrel etcher (second example) 
because the energy is more uniformly distributed. 
With regard to the plasma gas, any convenient or conventional plasma gas 
may be used, and 
CF4, N2, Argon, SF6, Helium, or any of the chlorine-based plasmas are 
satisfactory. 
In the second example, there is included a descum step. If the plasma is 
uniform, and the exposure of the photoresist is complete or overexposed, 
then there is no scum formation. An example in using the KTI resist is an 
exposure time at least 12 seconds with 20-25 MW/CM2 is satisfactory. If 
not fully exposed, and if not fixed with adequate energy in the plasma 
step, there can be caused in the first layer II a spewing of unexposed 
resist into the fine dimension during the second development. This 
manifests itself as a mottled blue-yellow scum typically between the 
lines. This, however, can be remedied by using an extended de-scum, which 
is set forth in the second example. 
FIG. 6 shows a partially cross-sectional view, not to scale, of a chip 
fabricated in accordance with the invention. 
FIG. 6 shows the wafer just prior to the implantation step. The substrate X 
is shown here with the silicon nitride layer XIV etched away in part, the 
silicon dioxide layer not being etched at all, and with previously 
diffused P and N regions in different portions of the base X. The first 
photoresist layer II covers the silicon nitride layer XII where it has not 
been etched by plasma. The second photoresist layer XX extends over a 
portion of the first photoresist layer II and onto the substrate overlying 
adjacently a portion of the SiO2 layer XII. A second portion of second 
photoresist XXa lies directly over the SiO2 layer towards the center, over 
a region of the substrate which is not to be implanted. It will be 
appreciated that FIG. 6 is only an example of one small portion of an 
integrated circuit chip. Other device configurations may be achieved with 
dual layer positive photoresists. Further modification might be in the 
etching step, not to cut into the substrate significantly, i.e., a very 
short plasma etch, just sufficient to fix the photoresist, then to be 
followed by another step. The invention has been described specifically 
with regard to plasma etching; however, it is not limited thereto and may 
include high temperature bakes for wet oxide etching, wet aluminum 
etching, or dry aluminum etching, as well as a host of other processes 
where a positive photoresist with high-baked temperatures is needed. 
There has been described two examples, including the best mode known by the 
inventor, for practicing the process of the invention, and there have been 
shown and described several examples of devices using the invention.