SEMICONDUCTOR DEVICE AND MANUFACTURE METHOD

A semiconductor device includes a substrate and an overlapping layer disposed on the substrate body. The substrate has a substrate body and a plurality of detection regions disposed on a top surface of the substrate body, in which one of the plurality of detection regions includes a luminescent material. The overlapping layer has a plurality of holes, and each one of the plurality of detection regions corresponds to each one of the plurality of holes. A method of manufacturing a semiconductor device is further provided.

BACKGROUND

Field of Invention

The present disclosure relates to a semiconductor device and a method of manufacturing a semiconductor device.

Description of Related Art

An issue of failing to detect overlay errors of holes (or trenches) through secondary electrons (such as using a scanning electron microscope (SEM)) exists while the holes (or the trenches) have a high aspect ratio.

For the foregoing reason, there is a need to solve the above-mentioned problem by providing a semiconductor device in which the overlay errors of the holes (or the trenches) can be detected regardless of whether the holes (or the trenches) have the high aspect ratio.

SUMMARY

Some embodiments of the present disclosure provide a semiconductor device including a substrate and an overlapping layer disposed on the substrate body. The substrate has a substrate body and a plurality of detection regions disposed on a top surface of the substrate body, in which one of the plurality of detection regions includes a luminescent material. The overlapping layer has a plurality of holes, and each one of the plurality of detection regions corresponds to each one of the plurality of holes.

In the foregoing, the top surface of the substrate body has a plurality of recesses, and each one of the plurality of detection regions corresponds to and is disposed in each one of the plurality of recesses.

In the foregoing, a top surface of the plurality of detection regions is coplanar with the top surface of the substrate body, and the substrate body surrounds a bottom portion of each one of the plurality of detection regions.

In the foregoing, the substrate body includes a first metal material, and one of the plurality of detection regions includes a second metal material, wherein the second metal material is the luminescent material.

In the foregoing, each one of the plurality of detection regions corresponds to and is disposed in each one of the plurality of holes, and a bottom surface of each one of the plurality of detection regions is coplanar with the top surface of the substrate body.

In the foregoing, one of the plurality of holes has an aspect ratio of from 5:1 to 100:1.

In the foregoing, the semiconductor device further includes a plurality of filling pillars, in which each one of the plurality of filling pillars is disposed on each one of the plurality of detection regions.

In the foregoing, each one of the plurality of filling pillars is directly disposed on each one of the plurality of detection regions and fills up each one of the plurality of holes.

Some embodiments of the present disclosure provide a method of manufacturing a semiconductor device including providing a substrate body; disposing an overlapping layer on the substrate body; forming a plurality of holes in the overlapping layer and exposing an exposed portion of the substrate body; disposing a plurality of detection regions on the substrate body or in the substrate body through the plurality of holes, wherein one of the plurality of detection regions includes a luminescent material; providing an electron beam propagating toward the plurality of detection regions to emit a luminescent signal from one of the plurality of detection regions; and determining an overlay error of the plurality of holes by comparing a practical position of one of the plurality of holes detected by the luminescent signal with a theoretical position of one of the plurality of holes.

In the foregoing, disposing the plurality of detection regions on the substrate body through the plurality of holes includes disposing a detection material including the luminescent material on the exposed portion of the substrate body.

In the foregoing, disposing the plurality of detection regions in the substrate body through the plurality of holes includes doping the luminescent material in the substrate body by an ion-implanting method.

In the foregoing, the substrate body includes a first metal material, and the luminescent material is a second metal material.

In the foregoing, the method further includes providing the electron beam propagating toward the overlapping layer while providing an electron beam propagating toward the plurality of detection regions; and determining a surface image of the overlapping layer by detecting secondary electrons reflected by the overlapping layer.

In the foregoing, the method further includes disposing a plurality of filling pillars on the plurality of detection regions.

DESCRIPTION OF THE EMBODIMENTS

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting of the present disclosure. Single forms used in the present specification such as “a”, “one” and “the” includes multiple forms such as “at least one”; “or” represents “and/or” unless described clearly. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises”, “comprising”, and/or “has”, “have”, “having” when used in this specification, specify the presence of stated features, areas, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, areas, integers, steps, operations, elements, components, and/or groups thereof.

Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. While the disclosure will be described in conjunction with embodiments, it will be understood that they are not intended to limit the disclosure to these embodiments. Therefore, the scope of the present disclosure is to be limited only by the appended claims.

Referring toFIG.1, illustrating a method100of manufacturing a semiconductor device, and the method100includes steps S110, S120, S130, S140, S150and S160. The steps S110to S160ofFIG.1are elaborated in connection with following figures.

Referring to step S110ofFIG.1andFIG.2, a substrate body210is provided.

In some embodiments, the substrate body210may include a first metal material, such as copper (Cu), copper alloy, aluminum (Al), aluminum alloy, tungsten (W), tungsten alloy, titanium (Ti), titanium alloy, tantalum (Ta), tantalum alloy, or a combination thereof. Alternatively, other applicable conductive materials may be used.

Referring to step S120ofFIG.1andFIG.3, an overlapping layer220is disposed on the substrate body210.

In some embodiments, the overlapping layer220may be, for example, a silicon substrate, a gallium arsenide substrate, a silicon germanium substrate, a silicon substrate on insulator (SOI) substrate, a multilayer or the like. For example, the overlapping layer220may be an insulating multilayer including an oxide layer and a carbon layer disposed on the oxide layer. In some other embodiments, the conductive materials may be used in the overlapping layer220.

In some embodiments, the overlapping layer220may be formed on the substrate body210by suitable method such as chemical vapor deposition (CVD), physical vapor deposition (PVD), or the like.

Referring to step S130ofFIG.1andFIG.4, holes222are formed in the overlapping layer220.

In some embodiments, an exposed portion212of the substrate body210is exposed after the holes222are formed. In some embodiments, the holes222have a high aspect ratio, such as from 5:1 to 100:1. For example, the holes222have an aspect ratio of 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 20:1, 30:1, 40:1, 50:1, 60:1, 70:1, 80:1, 90:1, 100:1, or a value within any interval defined by the above values. In some embodiments, the holes222are formed by patterning the overlapping layer220. It is noted that an overlay error of the holes222cannot be determined precisely since practical positions of the holes222with the high aspect ratio can hardly be positioned by a scanning electron microscope (SEM). Specifically, secondary electrons reflected by a sidewall224of the overlapping layer220and the exposed portion212of the substrate body210cannot be received by the SEM due to the high aspect ratio of the holes222.

Referring to step S140ofFIG.1andFIG.5A, detection regions230are disposed in the substrate body210through the holes222. Therefore, a semiconductor device200A is formed.

In some embodiments, the detection regions230and the substrate body210forms a substrate SUS, and each one of the detection regions230corresponds to each one of the holes222for detecting each of the position of the holes222in the following steps.

In some embodiments, the detection regions230are formed by doping the luminescent material LM, which can emit fluorescence or phosphorescence after absorbing enough energy, in the substrate body210by an ion-implanting method. That is, the detection regions230includes the first metal material of the substrate body210and the luminescent material LM doped in the first metal material. In some embodiments, the luminescent material LM is a second metal material, such as Cu+, Ag+, In+, V2+, Co2+, Sn2+, Eu2+, Mn2+, Ni2+, Pb2+, Bi3+, Pr3+, Nd3+, Sm3+, Eu3+, Gd3+, Tb3+, Dy3+, Ho3+, Tm3+, Yb3+, Ti3+, Ce3+, or a combination thereof, in which Nd3+may be served as an excellent candidate due to sharp and intense luminescence.

It should be emphasized that conductivity interference of the detection regions230to the substrate body210can be reduced while the luminescent material LM is selected to be the second metal material comparing with selection of an insulating material served as the luminescent material LM.

In some embodiments, after performing the ion-implanting method, the detection regions230are merged in the substrate body210so that the semiconductor device200A performs that a top surface214of the substrate body210has recesses216, each one of the detection regions230corresponds to and is disposed in each of the recesses216, in which the detection regions230are disposed on and contacts with the top surface214of the substrate body210for detecting each one of the position of the holes222in the following steps. In some embodiments, the top surface232of the detection regions230is coplanar with the top surface214of the substrate body210, and the substrate body210surrounds a bottom portion234of each one of the detection regions230.

It's noted that the disposition of the detection regions230merged in the substrate body210decreases the conductivity interference of the detection regions230to the substrate body210and can be easily performed by the ion-implanting method.

In some other embodiments, referring to step S140ofFIG.1andFIG.5B, the detection regions230are disposed on the substrate body210through the holes222.

FIG.5Bis basically similar toFIG.5A. The difference ofFIG.5BandFIG.5Ais that the semiconductor device200B ofFIG.5Bdisplays that a detection material including the luminescent material LM (not shown inFIG.5B) is disposed on the exposed portion212of the substrate body210to form the detection regions230. Therefore, a semiconductor device200B is formed.

In some embodiments, each one of the detection regions230corresponds to and is disposed in each one of the holes222, and a bottom surface236of each one of the detection regions230is coplanar with the top surface214of the substrate body210. That is, the bottom surface236of each one of the detection regions230directly contacts with the top surface214of the substrate body210and the sidewall224of the overlapping layer220.

In some embodiments, the detection regions230are formed by suitable method such as chemical vapor deposition (CVD), physical vapor deposition (PVD) or the like. In some embodiments, the detection material contains the luminescent material LM (such as the second metal material, not shown inFIG.5B) and an additive including an inorganic material, a polymer (such as resin), or a combination thereof. It should be emphasized that the conductivity interference of the detection regions230to the substrate body210can be reduced while the luminescent material LM (not shown inFIG.5B) is selected to be the second metal material comparing with selection of the insulating material served as the luminescent material LM (not shown inFIG.5B). In some other embodiments, the detection material is insulating and does not contain the conductive materials. For example, the luminescent material LM (not shown inFIG.5B) includes fluorescent protein (such as green fluorescent protein (GFP), enhanced EGFP, blue fluorescent protein (BFP), cyan fluorescent protein (CFP), red fluorescent protein (RFP), white GFP (wtGFP), yellow fluorescent protein (YFP), dsRed, mCherry, mVenus, mCitrine, tdTomato, mTurquoise2 or the like), but does not include the second metal material.

It's noted that the disposition of the detection regions230in the holes222and the bottom surface236of the detection regions230being coplanar with the top surface214of the substrate body210can be easily performed by semiconductor processes (such as CVD or PVD) and does not influence the structure of the substrate body210.

Referring to step S150ofFIG.1andFIG.6, an electron beam E1propagating toward the detection regions230is provided to emit a luminescent signal L from one of the detection regions230, in which the semiconductor device200A is provided merely for demonstration and is not limited thereto.

In some embodiments, an electron beam E1propagating toward the detection regions230is provided to emit the luminescent signals L from each one of the detection regions230while each one of the detection regions230includes the luminescent material LM.

In some embodiments, the electron beam E1is generated by a charged particle source S1, such as SEM. The electron beam E1provides the detection regions230with enough energy to allow the luminescent material LM (not shown inFIG.6) to emit the luminescent signal L. In some embodiments, the electron beam E1propagates toward the overlapping layer220as propagating toward the detection regions230, and then a surface image of the overlapping layer220is determined by detecting secondary electrons E2reflected by the overlapping layer220by using the charged particle source S1. That is, the electron beam E1is provided for generating the surface image of the overlapping layer220and the luminescent signal L from the detection regions230for the further positioning simultaneously.

Referring to step S160ofFIG.1andFIG.7, an overlay error of one of the holes222is determined according to the luminescent signal L. Specifically, the overlay error of one of the holes222is determined by comparing a practical position of one of the holes222detected by the luminescent signal L with a theoretical position of one of the holes222, in which the theoretical position is defined according to alignment marks of the substrate body210. For example, the overlay error in the x direction can be calculated by the following equation:

practical position in the x direction−theoretical position in the x direction

In some embodiments, the overlay error of each of the holes222is determined by comparing the practical position of each one of the holes222detected by the luminescent signal L with the theoretical position of each one of the holes222. In some embodiments, the luminescent signal L is detected to capture a luminescent picture by using a fluorescence microscope S2. In some embodiments, the luminescent picture obtained by the fluorescence microscope S2and the surface image obtained by the charged particle source S1(referring toFIG.6) can be combined to define the practical position of the hole222more precisely. It should be noted that the practical position of the hole222can hardly be detected by SEM through secondary electrons E2(referring toFIG.6) due to the high aspect ratio of the holes222. Comparatively, the detection region230including the luminescent material LM (not shown inFIG.7) achieves the detection of the practical position of the hole222by using the fluorescence microscope S2even though the holes222has the high aspect ratio.

In some embodiments, referring toFIG.8A, the filling pillars310are disposed on the detection regions230of the semiconductor device200A to form a semiconductor device300A once the overlay error of the hole222is within an acceptable range. That is, the overlay error of the hole222is determined before the formation of the filling pillars310in case of unacceptable bias of the filling pillars310caused by the bias of the holes222. In some embodiments, each one of the filling pillars310is disposed on each one of the detection regions230. For example, each one of the filling pillars310is directly disposed on each one of the detection regions230and fills up each one of the holes222.

In some embodiments, the filling pillar310includes a third metal material, is directly disposed on the detection regions230and fills up the holes222. For example, the filling pillar310can be served as a contact for contacting with a capacitor (not shown inFIG.8A). It should be emphasized that while the substrate body210and the filling pillar310are conductive, the interference of the detection regions230to the current flowing through the substrate body210and the filling pillar310can be reduced by selecting the conductive material (such as second metal material) to be the material of the detection regions230.

In some embodiments, referring toFIG.8B,FIG.8Bis basically similar toFIG.8A. The difference ofFIG.8BandFIG.8Ais that the semiconductor device300B ofFIG.8Bdisplays the filling pillars310are disposed on the detection regions230of the semiconductor device200B.

Some embodiments of the present disclosure provide a semiconductor device and method of manufacturing the semiconductor device. The semiconductor device includes the detection regions correspond to the holes of the overlapping layer, and the detection region includes the luminescent material. With the luminescent material of the detection regions, the overlay error of the holes with the high aspect ratio can successfully be determined.