Method of forming a pattern for a semiconductor device and method of forming the related MOS transistor

A method of forming a pattern for a semiconductor device, in which, two hard masks are included between an upper spin-on glass (SOG) layer and a lower etching target layer. The SOG layer is etched twice through two different patterned photoresists respectively to form a fine pattern in the SOG layer. Subsequently, an upper hard mask is etched by utilizing the patterned SOG layer as an etching mask so the upper patterned hard mask can have a fine pattern with a sound shape and enough thickness. A lower hard mask and the etching target layer are thereafter etched by utilizing the upper patterned hard mask as an etching mask, so portions of the etching target layer that are covered by the two hard masks can be well protected from the etching processes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a semiconductor fabrication, and more particularly, to a method of forming a pattern for a semiconductor device.

2. Description of the Prior Art

As sizes of semiconductor devices are designed as small as possible to catch up with the tendency of miniaturization, the patterning process becomes more and more important nowadays. In a traditional patterning process, the photoresist is patterned by one photolithography process, and thereafter serves as an etching mask for etching the underlying material layer. However, the miniaturization is limited by the exposing ability of current lithographic tools in traditional patterning process, because every lithographic tool has its critical exposure resolution of exposing gaps between lines and between spaces.

Accordingly, another pattern forming approach including two photolithography processes and one etching process is adopted when the pitch (the distance of centers of two neighboring structures) is smaller than 155 nanometers (nm). Please refer toFIG. 1, which is a schematic diagram illustrating the pattern forming approach including two photolithography processes. As shown inFIG. 1, one target pattern10, which is designed for a semiconductor device (not shown), is divided into two partial patterns12. Thus, the pitch of the target pattern10can be much smaller than the pitches of the partial patterns12, while the pitches of the partial patterns12should relate to the critical exposure resolution of the lithographic tool (not shown). As a result, the pitch of the target pattern10can be superior to the critical exposure resolution of the lithographic tool.

However, it is still some problems for applying the concept to various patterning processes in practice. When the pitch of contact holes is lower than 140 nm, the above-mentioned two-exposures-then-one-etching method fails because it is beyond the limitation of the current lithographic tools during the second exposure, and consequently contact holes lower than 140 nm pitch cannot be produced.

SUMMARY OF THE INVENTION

The objective of the present invention is to provide a method of forming a pattern for a semiconductor device, and a method of forming the related MOS transistor so that a finer pattern can be well transferred to an etching target layer.

The method of forming a pattern for a semiconductor device according to the present invention comprises steps as follows. First, a stacked structure is provided. The stacked structure includes a substrate, an etching target layer disposed on the substrate, a first hard mask disposed on the etching target layer, a second hard mask disposed on the first hard mask, a spin-on glass (SOG) layer disposed on the second hard mask, and a first patterned photoresist disposed on the SOG layer. Subsequently, a first etching process is performed on the SOG layer to transfer a first pattern to the SOG layer by utilizing the first patterned photoresist as an etching mask. Next, the first patterned photoresist is removed. Furthermore, a second patterned photoresist is formed on the SOG layer having the first pattern. Next, a second etching process is performed on the SOG layer to transfer a second pattern to the SOG layer by utilizing the second patterned photoresist as an etching mask. Following that, the second patterned photoresist is removed. Thereafter, the second hard mask is etched by utilizing the patterned SOG layer as an etching mask. Afterward, the first hard mask and the etching target layer are etched by utilizing the patterned second hard mask as an etching mask.

In another aspect of the present invention, the second hard mask includes an amorphous carbon layer disposed on the first hard mask, and a dielectric anti-reflection coating (DARC) layer disposed on the amorphous carbon layer.

The SOG layer is used for having a finer pattern defined by a 2P2E process (a process of forming a pattern in a material layer through two photolithographic exposures and two etching processes). Since the SOG layer may become thinner due to two etching processes, the fine pattern is transferred to the second hard mask so the patterned second hard mask can have a fine pattern with a sound shape and enough thickness. The patterned second hard mask can protect both the covered portions of the first hard mask and the covered portions of the etching target layer in the following process of etching the etching target layer, while the first hard mask can also protect the etching target layer. Therefore, both the patterned first hard mask and the patterned etching target layer can have sound shapes. Accordingly, the patterned etching target layer can be further protected in the subsequent procedures, such as another etching process or an epitaxial growth process, by the well patterned first hard mask.

DETAILED DESCRIPTION

The present invention provides a patterning method, where two hard masks are included between a lower etching target layer and an upper SOG layer patterned by a 2P2E process. Methods of the present invention can be applied to any semiconductor patterning process to form a well-patterned structure, such as a gate, an interlevel dielectric (ILD) contact hole or an STI structure.

FIGS. 2 through 9indicate a method of forming a pattern for a semiconductor device according to an embodiment of the present invention, whereFIG. 4Ashows the top-view of the semiconductor structure shown inFIG. 4, andFIG. 7Ashows the top-view of the semiconductor structure shown inFIG. 7. First, as shown inFIG. 2, a stacked structure102is provided. The stacked structure102includes a substrate104, an etching target layer106disposed on the substrate104, a first hard mask108disposed on the etching target layer106, a second hard mask110disposed on the first hard mask108, a SOG layer112disposed on the second hard mask110, and a first patterned photoresist114disposed on the SOG layer112, where the second hard mask110includes an amorphous carbon layer116disposed on the first hard mask108, and a DARC layer118disposed on the amorphous carbon layer116.

The substrate104may be a semiconductor or SOI substrate. The etching target layer106can be a single film, or includes multiple material films. The first hard mask108can include oxide, silicon nitride (SixNy), silicon-rich nitride, silicon oxynitride or silicon carbide, but not limited thereto. The DARC layer118can include silicon nitride, oxide, SiON or SiC, and functions to protect the amorphous carbon layer116from being damaged during photoresist removing. The first patterned photoresist114can include any photosensitive materials, such as 193 nm photoresist, which may be relatively thin, and accordingly, the resolution may be improved. In other embodiments, the second hard mask110can contain amorphous carbon, SiN, oxide, SiON, SiC or any combination thereof.

Subsequently, as shown inFIG. 3, an etching process, such as dry etching, is performed on the SOG layer112to transfer a first pattern to the SOG layer112by utilizing the first patterned photoresist114as an etching mask. Next, as shown inFIG. 4andFIG. 4A, the remaining first patterned photoresist114is removed, and the first pattern of the SOG layer112is visible in top-view.

Furthermore, as shown inFIG. 5, a bottom anti-reflection coating (BARC) layer120is formed on the SOG layer112having the first pattern, and thereafter a second patterned photoresist122is formed on the BARC layer120. The BARC layer120can fill openings of the SOG layer112, and can contain 365 nm (I-line) photoresist, which may improve adhesion and provide a function of anti-reflection. The second patterned photoresist122can include any photosensitive materials, such as 193 nm photoresist.

Next, as shown inFIG. 6, another etching process is performed on the BARC layer120and the SOG layer112to transfer a second pattern to the SOG layer112by utilizing the second patterned photoresist122as an etching mask, while portions of the BARC layer120not covered by the second patterned photoresist122are also etched. Following that, as shown inFIG. 7andFIG. 7A, the remaining second patterned photoresist122and the remaining BARC layer120are removed. A target pattern, which is a combination of the first and second patterns, is shown in top-view. The SOG layer112is used for having the finer pattern defined by the 2P2E process, while the SOG layer112—is thinner due to the two etching processes.

Thereafter, as shown inFIG. 8, another etching process is carried out on the second hard mask110by utilizing the patterned SOG layer112as an etching mask, so the target pattern can be transferred to the second hard mask110. It is noted that the patterned SOG layer112is exposed and etched during this etching process, so it may be totally consumed after this etching process. This explains the absence of the SOG layer112inFIG. 8. Furthermore, the thickness of the SOG layer is well selected so that the thickness is enough to protect the underlying second hard mask but not remained too much after this etching process. Since the second hard mask110can be prevented from suffering the 2P2E process, the patterned second hard mask110can have a finer pattern with a sound shape and enough thickness (the target pattern).

Afterward, as shown inFIG. 9, another etching process is carried out on the first hard mask108and the etching target layer106by utilizing the patterned second hard mask110as an etching mask. In this etching procedure, the thickness of the whole second hard mask110is reduced. Generally, the DARC layer118may be completely consumed. The patterned second hard mask110can protect both the covered portions of the first hard mask108and the covered portions of the etching target layer106in this etching process, while the first hard mask108can also protect the etching target layer106simultaneously. Therefore, both the patterned first hard mask108and the patterned etching target layer106can have sound shapes and enough thicknesses.

Some embodiments of the present invention are described hereinafter to show various semiconductor structures formed by the above method of the present invention, as shown inFIG. 10, where the amorphous carbon layer116is removed after the etching target layer106is partially etched. It should be noted that like numbered numerals designate similar or the same parts, regions or elements. According to the above method, different patterns can be formed in different etching target layer having various materials. AsFIG. 10diagrammatically shows, a gate124of a MOS transistor (this etching target layer106includes a single or composite gate dielectric layer and a conductive layer, such as poly-silicon or metal, disposed on the gate dielectric layer), a plug hole126, such as an ILD contact hole or an IMD via hole, (this etching target layer106can be ILD or IMD film stack, including oxide, SiC, SiON, SiN, low-k material, metal material or any combination thereof) and a STI recess128(this etching target layer106is a film stack composed of a substrate material such as Si, a thin dielectric layer such as an oxide layer and a hard mask layer such as a SiN layer) can be formed according to the above method.

The resulting stacked structure102may be subsequently processed after etching target layer is patterned as desired in other semiconductor manufacturing processes. For example, the patterned first hard mask108can be removed from the surface of the patterned etching target layer106, or can be kept to protect the patterned etching target layer106in the subsequent procedures, such as another etching process, an epitaxial growth process according to the process design.FIGS. 11 through 13indicate a method of forming a MOS transistor in the present invention, where the gate124of this MOS transistor is formed by the method shown inFIG. 2throughFIG. 9, and therefore has a structure similar to the gate124shown inFIG. 10.

As shown inFIG. 11, an ion implantation process can be optionally performed to form lightly doped drains (LDD)132in the substrate104at opposite sides of the gate124. Thereafter, a spacer130is formed on the sidewall of the gate124. The spacer may include an L-shaped or linear offset spacer, D-shaped spacer, of a combination thereof and comprise a material such as oxide or nitride.

Next, as shown inFIG. 12, the exposed portions of the substrate104, i.e. the predetermined regions for recess, is partially removed using the patterned first hard mask layer108and the spacer130as an etching mask to form recesses134in the substrate104. The process for forming the recesses134may be dry etching and/or wet etching.

Afterward, as shown inFIG. 13, an epitaxial growth process, such as selective epitaxial growth (SEG) process, is performed to form an epitaxial layer136in each of the recesses134. For example, a SiGe epitaxial layer may be used for manufacturing a PMOS, and a SiC epitaxial layer may be used for manufacturing an NMOS, but not limited thereto. The epitaxial layer may rise to have a height greater than that of the top plane of the original substrate. Since the patterned first hard mask108can have a sound shape and enough thickness, the patterned first hard mask108can further protect the underlying gate124from being exposed to the epitaxial growth process, and avoids gate bumps.

In the subsequent procedures, the patterned first hard mask108can be removed form the surface of the patterned etching target layer106, or can be kept to protect the patterned etching target layer106as required.

In sum, the present invention not only can form a finer pattern in the etching target layer, but also can provide great protection to the etching target layer in the manufacturing processes. In addition, the method of the present invention is easily integrated with current processes and has a low cost, and accordingly can be well applied to semiconductor manufacturing processes.