Structure of semiconductor device with funnel-shaped inter-level connection and method of manufacturing it

Abstract: A semiconductor device has a funnel shaped contact window (30) for providing an inter-level connection between a lower silicon or polysilicon film (22) and an upper metal wiring strip (32), and the funnel shaped contact window is formed in an inter-level insulating film structure (27) consisting of a lower insulating film (28) of phosphosilicate glass and an upper insu­ lating film (29) of silicon dioxide, since an isotropical etching is firstly applied to the silicon dioxide film and followed by an anisotropical etching to the phosphosilicate glass film by using the same mask layer, the lower portion of the contact window is smaller in cross sectional area than the upper portion, and the funnel shaped contact window thus formed is effective to create a smooth topography of an upper metal wiring strip for preventing from undesirable disconnection.

Description: This invention relates to a semiconductor device and, more particularly, to the structure of an interconnection between a lower conductive layer and an upper conductive layer, as well as to a method of manufacturing such a device. A semiconductor device is fabricated into a multiple level structure, and inter-level connections provide the electrical paths between the different levels. In a semiconductor device an upper level wiring strip per se provides the inter-level connection, and such an inter-level connection is produced through the following steps. Namely, when a lower level conductive film is formed, an inter-level insulating film is deposited over the entire surface, and a contact window is, then, formed in the inter-level conductive layer for partially exposing the lower level conductive layer. A conductive metal such as aluminum is deposited over the entire surface, so that the aluminum film penetrates into the contact window, then being patterned so as to form the upper level wiring strip. In this example, a smooth topography hardly takes place, and, accordingly, a poor coverage is causative of undesirable disconnection. Reference is directed in this connection to Patent Abstracts of Japan, vol. 9, no. 328 (E-369) [2051], 24 December 1985 and JP-A-60 160653; EP-A-0 223 637; and US-A-4 618 878. This art discloses the provision of an insulating layer from upper and lower films, the contact window comprising aligned apertures in the respective films, the cross section of the aperture in the upper film being greater than the cross section of the aperture in the lower film. US-A-4 692 786 discloses a semiconductor device in which an insulating layer comprises a lower silica layer, a nitride layer and an upper silica layer. The thickness of the upper silica layer is approximately 5 to 10 times greater than that of the lower silica layer to minimise undercutting of the nitride layer by excessive etching of the lower silica layer. Contact windows are formed in the insulating layer. An inter-level interconnection formed of TiW is established between an upper conductive layer of aluminium and a conductive region in the semiconductor substrate through the contact windows which widen towards the upper surface of the insulating layer. Another structure has been proposed for provision of a solution inherent in such a prior art inter-level connection. Referring to Fig. 1 of the drawings, an n-type impurity region 1 is formed in a p-type silicon substrate 2, and phosphosilicate glass is deposited to a thickness of about 500 nm (5000 angstroms) over the entire surface of the structure by using a chemical vapor deposition technique. The phosphosilicate glass film 3 is anisotropically etched away by using a reactive etching technique to from a contact window 4, and a polysilicon is deposited to a thickness of about 1 micron by using an usual chemical vapor deposition technique. Since the contact window 4 is formed in the phosphosilicate glass film 3, the polysilicon fills the contact window and further spreads over the phosphosilicate glass film 3, thereby providing a generally flat top surface. The polysilicon thus deposited is uniformly removed through an etch-back technique until the top surface of the phosphosilicate glass film 3 is exposed, so that a piece of polysilicon 5 is left in the contact window 4. When the contact window 4 is filled with the piece of polysilicon 5, an aluminum is deposited over the entire surface by using a sputtering technique, and the aluminum film is patterned to form an upper wiring strip 6. However, a problem is encountered in the prior art structure in that undesirable cracks still take place along the periphery of the contact window 4. This is because of the fact that the piece of polysilicon 5 does not completely fill the contact window 4, and this step configuration is causative of the recess formed above the contact window 4. When the recess 7 is present, cracks are much more liable to be produced. The reason why the step configuration takes place is that the polysilicon film of 1 micron hardly creates a strictly flat top surface, and the inequality sometimes causes the piece of polysilicon 5 not to be coplanar with the phosphosilicate glass film 3. It is therefore an important object of the present invention to provide a semiconductor device which has inter-level connections each free from disconnection. To accomplish these objects, the present invention proposes to form a funnel shaped inter-level connection. In accordance with a first aspect of the present invention, there is provided a semiconductor device comprising a semiconductor substrate, a lower conductive region provided in an upper surface of said substrate or a lower conductive layer provided on said substrate, an inter-level insulating film structure provided on said lower conductive region or layer, a contact window being formed in said inter-level insulating film structure, said inter-level insulating film structure comprising a lower insulating film defining a lower part of said contact window, and an upper insulating film defining an upper part of said contact window, said upper part and said lower part providing a funnel-shape to said contact window such that the width of the upper part of said contact window increases towards the upper surface thereof, an upper conductive layer formed on said inter-level insulating film structure extending over said contact window and electrically connected to said lower conductive region or layer, and a doped polysilicon inter-level connection provided within said contact window to substantially fill said contact window so that the upper surface of the connection is substantially level with the upper surface of said upper insulating film and contacted between said lower conductive region or layer and said upper conductive layer. In accordance with a second aspect of the present invention, there is provided a method of manufacturing a semiconductor device comprising the steps of forming a silicon structure having doped regions and having either in an upper surface thereof a lower conductive region or a lower conductive layer provided thereon to which electrical contact is to be made; depositing an inter-level insulating film structure to cover said lower conductive region or layer; said inter-level insulating film structure comprising an upper insulating film and a lower insulating film; forming a mask on said upper insulating film; forming a funnel shaped opening in said inter-level insulating film above said conductive region or layer by successively isotropically etching the upper insulating layer and anisotropically etching the lower insulating layer using said mask to provide a contact window to said lower conductive region or layer; removing said mask; depositing a doped polysilicon film on the surface of the thus formed structure to fill said funnel shaped opening with doped polysilicon; isotropically etching back said film to expose the top surface of said upper insulating film thereby leaving an inter-level connection of polysilicon which substantially fills said contact window; and depositing an upper conductive layer on said inter-level insulating film and said interlevel connection to establish electrical contact with said inter-level connection and thereby with said lower conductive region or layer. The features and advantages of a semiconductor device and its manufacturing method according to the present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which: Fig. 1 is a cross sectional view showing the structure of a prior art semiconductor device; Fig. 2 is a cross sectional view showing the structure of a semiconductor device embodying the present invention; Figs. 3A to 3F are cross sectional views showing the process sequence through which the semiconductor device shown in Fig. 2 is fabricated; and Fig. 4 is a cross sectional view showing the structure of another semiconductor device embodying the present invention. Referring to Fig. 2 of the drawings, a semiconductor device according to the present invention is fabricated on a p-type single crystal silicon substrate 21. In the silicon substrate 21 are formed n-type source and drain regions 22 and 23 which are spaced apart from each other by a channel forming area 24. A thin gate oxide film 25 is grown over the channel forming area 24, and a gate electrode 26 is provided on the gate oxide film 25. The source and drain regions 22 and 23, the gate oxide film 25 and the gate electrode 26 as a whole constitute a field effect transistor. A large number of field effect transistors are formed on the silicon substrate 21, however, only one the field effect transistor is shown in Fig. 2 for the sake of simple illustration. The silicon substrate 21 as well as the gate electrode 26 are covered with an inter-level insulating film structure 27 consisting of a lower insulating film 28 of a phosphosilicate glass film 28 and an upper insulating film 29 of a silicon oxide, and a contact window 30 is formed in the inter-level insulating film structure 27. The contact window has lower and upper portions passing through the lower insulating film 28 and the upper insulating film 29, respectively, and the lower portion is smaller in the cross sectional area than the upper portion. The contact window thus shaped is of the generally funnel configuration. The funnel shaped contact window 30 is filled with a piece of an n-type impurity doped polysilicon 31 the top surface of which is only slightly lower than the top surface of the upper insulating film 29. On the inter-level insulating film structure 27 extends an upper wiring strip 32 of an aluminum which is in contact with the piece of the polysilicon 31. The upper wiring strip 32 serves as, for example, a power supply line, and the electric power is supplied through the upper wiring strip 32 and the piece of polysilicon 31 to the source region 22 of the field effect transistor. Description is hereinbelow made on a process sequence for fabricating the semiconductor device with reference to Figs. 3A to 3F. First, the single crystal silicon substrate 21 is prepared, and the thin gate oxide film 25 is thermally grown on the silicon substrate 21. Subsequently, n-type impurity atoms are doped into the silicon substrate 21 so as to form the source and drain regions 22 and 23 in a self-align fashion with respect to the gate electrode 26. An essential part of the resultant structure is shown in Fig. 3A. The phosphosilicate glass is firstly deposited to a thickness of about 500 nm (5000 angstroms) on the entire surface of the structure by using a chemical vapor deposition technique, and silicon dioxide is, then, deposited to a thickness of about 100 nm (1000 angstroms) on the phosphosilicate glass film 28 by using a usual chemical vapor deposition technique. The phosphosilicate glass is smaller in etching rate than the silicon dioxide. In fact, the phosphosilicate glass is of the order of 45 nm (450 angstroms) per minute, but the silicon dioxide is as large as 80 nm (800 angstroms) per minute. The resultant structure of this stage is shown in Fig. 3B. A photoresist solution is spun onto the silicon dioxide film 29, and is, then, patterned through usual lithographic techniques so that a mask layer 33 is provided on the silicon dioxide film 29. The mask layer 33 exposes a part of the silicon dioxide film 29 where the upper portion of the funnel shaped contact window 30 will be shaped in the later stage. The exposed area of the silicon dioxide film 29 is isotropically etched by using a wet etching technique as shown in Fig. 3C, and the recess 34 formed in the silicon dioxide film 29 is about 2 micron in diameter. Since the recess 34 is formed in an isotropical manner, the upper periphery of the recess 34 extends beneath the bottom surface of the mask layer 33. After the formation of the recess 34, the phosphosilicate glass film 28 is anisotropically etched by using the mask layer 33, and a hollow space 35 is formed in the phosphosilicate glass film 28. The hollow space 35 is square in cross section, and the square is measured as 1 micrometer x 1 micrometer. The recess 34 and the hollow space 35 form in combination the funnel shaped contact window 30 as shown in Fig. 3D. A polysilicon 36 is then deposited to a thickness of about 1 micron over the entire surface of the structure, and the polysilicon 36 penetrates into the funnel shaped contact window 30. The resultant structure of this stage is shown in Fig. 3E. An etch-back technique is, then, applied to the polysilicon film 36. Namely, the polysilicon film 36 is isotropically etched away by using a dry etching technique until the top surface of the silicon dioxide film 29 is exposed. The top surface of the piece of the polysilicon 31 may be slightly lowered with respect to the top surface of the silicon dioxide film 29 because of the unequal top surface of the doped polysilicon 36. However, the top surface of the piece of the polysilicon 31 is much closer to the top surface of the silicon dioxide film 29 by virtue of the funnel shaped contact window 30. N-type impurity atoms are ion implanted into the piece of the polysilicon 31 for providing an ohmic contact. The resultant structure of this stage is shown in Fig. 3F. An aluminum is sputtered on the entire surface of the structure, and the aluminum film is patterned to form the upper wiring strip 32. On the entire surface of the structure is further deposited a passivation film, however, the passivation film is omitted from the structure shown in Fig. 2. Since the piece of the doped polysilicon 31 substantially fills the funnel shaped contact window 30, a smooth topology is created, and, accordingly, no cracks takes place in the upper wiring strip 32. Turning to Fig. 4 of the drawings, another semiconductor device is fabricated on a p-type single crystal silicon substrate 41, and the semiconductor device has a field effect transistor which is formed with n-type source and drain regions 42 and 43, a gate oxide film 44 and a gate electrode 45. An insulating film 46 covers the semiconductor substrate 41 and the field effect transistor, and a lower conductive film 47 of a polysilicon is brought into contact with the source region 42 through a contact window formed in the insulating film 46. On the lower conductive film 47 is provided an inter-level insulating film structure 48 which consists of a lower insulating film 49 of a phosphosilicate glass and an upper insulating film 50 of silicon dioxide. A funnel shaped contact window 51 is formed in the inter-level insulating film structure 48, and is filled with an n-type impurity doped polysilicon 52. On the inter-level insulating film structure 48 is patterned an upper wiring strip 53 of aluminium which is in contact with the piece of the doped polysilicon 52 for electrical conduction. A passivation film 54 is deposited over the entire surface of the structure for providing protection. In this instance, the funnel shaped contact window 51 is also effective for preventing the upper wiring strip 53 from undesirable cracks. The process sequence is similar to that illustrated in Figs. 3A to 3F, and, for this reason no description is incorporated. As will be understood from the foregoing description, the funnel shaped contact window according to the present invention is advantageous over the prior art column shaped contact window in the improved coverage and in the smooth topography. While the present invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description rather than limitation and that changes may be made to the invention without departing from its scope as defined by the appended claims.

Claims: A semiconductor device comprising a semiconductor substrate (21), a lower conductive region (22) provided in an upper surface of said substrate (21) or a lower conductive layer (47) provided on said substrate (21), an inter-level insulating film structure (27, 48) provided on said lower conductive region or layer, a contact window (30, 51) being formed in said inter-level insulating film structure, said inter-level insulating film structure (27, 48) comprising a lower insulating film (28, 49) defining a lower part of said contact window, and an upper insulating film (29, 50) defining an upper part of said contact window, said upper part and said lower part providing a funnel-shape to said contact window such that the width of the upper part of said contact window increases towards the upper surface thereof, an upper conductive layer (32, 53) formed on said inter-level insulating film structure extending over said contact window and electrically connected to said lower conductive region or layer, and a doped polysilicon inter-level connection (31, 52) provided within said contact window to substantially fill said contact window so that the upper surface of the connection (31, 52) is substantially level with the upper surface of said upper insulating film (29, 50) and contacted between said lower conductive region or layer and said upper conductive layer. A device according to Claim 1, wherein said upper conductive layer is of aluminium. A method of manufacturing a semiconductor device comprising the steps of forming a silicon structure (21-24; 41-43) having doped regions and having either in an upper surface thereof a lower conductive region (22) or a lower conductive layer (47) provided thereon to which electrical contact is to be made; depositing an inter-level insulating film structure (27, 48) to cover said lower conductive region or layer; said inter-level insulating film structure comprising an upper insulating film (29, 50) and a lower insulating film (28, 49); forming a mask (33) on said upper insulating film; forming a funnel shaped opening in said inter-level insulating film above said conductive region or layer by successively isotropically etching the upper insulating layer and anisotropically etching the lower insulating layer using said mask to provide a contact window (30, 51) to said lower conductive region or layer; removing said mask; depositing a doped polysilicon film (36) on the surface of the thus formed structure to fill said funnel shaped opening with doped polysilicon; isotropically etching back said film (36) to expose the top surface of said upper insulating film (29, 50) thereby leaving an inter-level connection (31, 52) of polysilicon which substantially fills said contact window (30, 51); and depositing an upper conductive layer (32, 53) on said inter-level insulating film and said interlevel connection to establish electrical contact with said inter-level connection (31, 52) and thereby with said lower conductive region or layer. A method according to Claim 3, wherein said upper insulating film (29, 50) is formed of silicon dioxide and said lower insulating film (28, 49) is formed of phosphosilicate glass.

Inventors: YAMAZAKI YASUSHI, YAMAZAKI, YASUSHI, YAMAZAKI, YASUSHI, C/O NEC CORPORATION
Applicants: NIPPON ELECTRIC CO, NEC CORPORATION
Application year: 1990
Main classification: H01L23
IPC codes: H01L23, H01L21