Abstract:
A method for forming hybrid low-k film stack is disclosed, in which an organic spin-on low-k material and CVD low-k material are combined to avoid thermal stress effect. This invention also provides a method for applying hybrid low-k film stack to dual damascene process.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention generally relates to a method for forming a semiconductor device, and more particularly to a method for forming hybrid low-k film stack to avoid thermal stress effect.  
           [0003]    2. Description of the Prior Art  
           [0004]    It is the nature of semiconductor physics that as the feature sizes are scaled down, the performance of internal devices, such as device speed, as well as the functional capability improves. The overall circuit speed, however, becomes more dependent upon the propagation speed of the signals along the interconnects that connect the various devices together. With the advent of very and ultra large scale integration (VLSI and ULSI) circuits, it has therefore become even more important that the metal conductors that form the interconnections between devices as well as between circuits in a semiconductor have low resistivity for high signal propagation. Copper is often preferred for its low resistivity, as well as for resistance to electromigration and stress voiding properties.  
           [0005]    In the manufacture of devices on a semiconductor wafer, it is now the practice to fabricate multiple levels of conductive (typically metal) layers above a substrate. The multiple metallization layers are employed in order to accommodate higher densities as device dimensions shrink well below one micron design rules. Likewise, the size of interconnect structures will also need to be shrink, in order to accommodate the smaller dimensions. Thus, as integrated circuit technology advances into the sub-0.25 micron range, more advanced interconnect architecture and new materials are required.  
           [0006]    Low dielectric constant materials have the advantage that higher performance IC devices may be manufactured with minimal increases in chip size. The reduced capacitance given by these materials permits shrinking spacing between metal lines to below 0.25 μm and the ability to decease the number of levels of metal in a device. The technologies being considered for low-k applications are CVD or spin-on of inorganic or organic polymeric materials. More recent advances in Si—O based polymer chemistry have seen the development of new materials that have k=2.5-3.0 by changing the structure of the polymer.  
           [0007]    Low-k material is popularly used to improve integrated circuit performance of RC delay below 0.18 micron technology. However, thermal stress effect severes on these low-k materials, especially organic spin-on material, for instance SiLK. On the other hand, chemical vapor deposition low-k materials have better thermal conduction than organic spin-on materials. Therefore, it is the most important critical point in semiconductor processes that how to combination of these two kind of materials is inevitable beyond 0.13 generation.  
           [0008]    For the foregoing reasons, there is a necessary for a method for forming hybrid low-k film stack to avoid thermal stress effect to reduce thermal stress effect issue.  
         SUMMARY OF THE INVENTION  
         [0009]    In accordance with the present invention, a method is provided for forming hybrid low-k film stack to avoid thermal stress effect that substantially can be used to decrease thermal stress in conventional process.  
           [0010]    One object of the present invention is to provide a method for forming hybrid low-k film stack to avoid thermal stress effect to decrease thermal stress.  
           [0011]    Another object of the present invention is to provide a method for forming hybrid low-k film stack to avoid thermal stress effect to apply below 0.13 micron process.  
           [0012]    In order to achieve the above object, the present invention provides a method for forming hybrid low-k film stack is disclosed, in which an organic spin-on low-k material and CVD low-k material are combined to avoid thermal stress effect. This invention also provides a method for applying hybrid low-k film stack to dual damascene process. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by referring to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:  
         [0014]    [0014]FIG. 1A to FIG. 1H are cross-sectional views of a method for forming hybrid low-k film stack to avoid thermal stress effect on via in accordance with one preferred embodiment of the present invention; and  
         [0015]    [0015]FIG. 2A to FIG. 2E are cross-sectional views of a method for forming hybrid low-k film stack to avoid thermal stress effect on via in accordance with another preferred embodiment of the present invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0016]    The semiconductor devices of the present invention are applicable to a broad range of semiconductor devices and can be fabricated from a variety of semiconductor materials. While the invention is described in terms of a single preferred embodiment, those skilled in the art will recognize that many steps described below can be altered without departing from the spirit and scope of the invention.  
         [0017]    Furthermore, there is shown a representative portion of a semiconductor structure of the present invention in enlarged, cross-sections of the two dimensional views at several stages of fabrication. The drawings are not necessarily to scale, as the thickness of the various layers are shown for clarity of illustration and should not be interpreted in a limiting sense. Accordingly, these regions will have dimensions, including length, width and depth, when fabricated in an actual device.  
         [0018]    [0018]FIG. 1A to FIG. 1H are cross-sectional views of a method flow for forming hybrid low-k film stack to avoid thermal stress effect in accordance with one preferred embodiment of the present invention.  
         [0019]    Referring to FIG. 1A, firstly, a semiconductor substrate  100  is provided, and a metal layer  102  is formed over a semiconductor substrate  100 . The metal layer  102  comprises copper. Since copper has higher resistance to electromigration and lower electrical resistivity, it is a kind of preferred material for interconnect wiring. Then, a first cap layer  104  is formed over a metal layer  102 . The first cap layer  104  comprises silicon nitride. A first dielectric layer  106  is formed on the first cap layer  104  by chemical vapor deposition (CVD). The first dielectric layer  106  comprises of a low-k dielectric, such as Coral, the first dielectric layer  106  has better thermal conduction by chemical vapor deposition. In the embodiment, material of this layer is preferably Coral. The first dielectric layer  106  is typically deposited to a thickness of about 2500 angstroms. A second dielectric layer  108  is formed on the first dielectric layer  106  by spin-on. The second dielectric layer  108  comprises of a low-k dielectric, such as SiLK and hydrogen silsesquioxane (HSQ), the second dielectric layer  108  has better planarization due to spin-on. In the embodiment, material of this layer is preferably SiLK. The second dielectric layer  108  is typically deposited to a thickness of about 2500 angstroms. The second cap layer  110  comprises silicon nitride (SiN) or silicon carbide (SiC). A first hardmask layer  112  is formed over the second cap layer  110 . The first hardmask layer  112  comprises TEOS. Then, a first bottom anti-reflective coating (BARC) layer  114  is formed on the second cap layer  110 . A first photoresist layer  116  is deposited on the first bottom anti-reflective coating (BARC) layer  114 . The first photoresist layer  116  has a trench opening  117  by using conventional lithographic technology. Then, the bottom anti-reflective coating(BARC) layer  114  is etch by using the first photoresist layer  116  as a mask.  
         [0020]    Referring to FIG. 1B, the first hardmask layer  112  has a trench opening  117   a  by using conventional lithographic technology. Then, the second cap layer  110  is etch by using the first hardmask layer  112  as a mask. The trench opening  117   a  is formed by dry etching method. A first photoresist layer  116  is then removed. Then, the bottom anti-reflective coating (BARC) layer  114  is also removed at the same time.  
         [0021]    Referring to FIG. 1C, after etching, the second dielectric layer  108  is dished about 300˜500 angstroms because the etch selectivity of the second dielectric layer  108  is different from the second cap layer  110 . Then, The trench opening  117   b  is formed by anisotropically etching method. The use of CxHyFz, (such as CHF 3 ), O 2 , and argon as etchants for the second cap layer  110 .  
         [0022]    Referring to FIG. 1D, a dielectric layer  118  is formed on the second dielectric layer  108  and filled in the trench opening  117   b  by spin-on. The dielectric layer  118  is SiLK, and a low-k dielectric. A second hardmask layer  120  is formed over the dielectric layer  118 . The second hardmask layer  120  comprises TiN. Then, a second bottom anti-reflective coating (BARC) layer  122  is formed on the second hardmask layer  120 . A second photoresist layer  124  is deposited on the second bottom anti-reflective coating (BARC) layer  122 . The second photoresist layer  124  has a via opening  125  by using conventional lithographic technology. Then, the bottom anti-reflective coating (BARC) layer  122 , the second hardmask layer  120 , the SiLK layer  118  and the second dielectric layer  108  are etch by using the second photoresist layer  124  as a mask.  
         [0023]    Referring to FIG. 1E, a via opening  125   a  is formed by dry etching method. Then, a second photoresist layer  124  is then removed. Then, the second bottom anti-reflective coating (BARC) layer  122  is also removed at the same time. The use of CxHyFz, (such as CHF 3 ), O 2 , and argon as etchants for the second hardmask layer  120 . Moreover, the dielectric layer  118  and the second dielectric layer  108  are used of N 2 /H 2  as etchants.  
         [0024]    Referring to FIG. 1F, the first dielectric layer  106  on the first cap layer  104  is etched and simultaneously a via opening  125   b  is formed by using of N 2 , C 4 H 8 , and argon as etchants. The via opening  125   b  is formed by anisotropically etching method. The second hardmask layer  120  and a portion of the dielectric layer  118  are removed because the etch selectivity of the first dielectric layer  106  is different from the second hardmask layer  120  and the dielectric layer  118 . The portion of the dielectric layer  118  is removed become a dielectric layer  118   a.    
         [0025]    Referring to FIG. 1G, the dielectric layer  118   a  and the sidewall of the second dielectric layer  108  are etched and simultaneously to form a trench opening  127  stopping on the first dielectric layer  106  by using of N 2 /H 2  as etchants. Then, the first dielectric layer  106  having a via opening  125   c . The trench opening  127  is formed by anisotropically etching method.  
         [0026]    Referring to FIG. 1H, the first cap layer  104  is etched and simultaneously a via opening  125   d  is formed on the metal layer  102  by using of N 2 , C 4 F 8 , O 2 , and argon as etchants. Then, a via opening  125   d  is formed by dry etching method. The etch process can cause corner on the top rim of the first dielectric layer  106 .  
         [0027]    [0027]FIG. 2A to FIG. 2E are cross-sectional views of a method for forming hybrid low-k film stack to avoid thermal stress effect in accordance with another preferred embodiment of the present invention.  
         [0028]    Referring to FIG. 2A, firstly, a semiconductor substrate  100  is provided, and a metal layer  202  is formed over a semiconductor substrate  200 . The metal layer  202  comprises copper. Since copper has higher resistance to electromigration and lower electrical resistivity. The copper is preferred material for interconnect wiring. Then, a first cap layer  204  is formed over a metal layer  202 . The first cap layer  204  comprises silicon nitride. A first dielectric layer  206  is formed on the first cap layer  204  by chemical vapor deposition (CVD). The first dielectric layer  206  comprises of a low-k dielectric, such as Coral and, the first dielectric layer  206  has better thermal resistance by chemical vapor deposition. In the embodiment, material of this layer is preferably Coral. The first dielectric layer  106  is typically deposited to a thickness of about 2500 angstroms. A second dielectric layer  208  is formed on the first dielectric layer  106  by spin-on. The second dielectric layer  208  comprises of a low-k dielectric, such as SiLK and hydrogen silsesquioxane (HSQ), the second dielectric layer  208  has better planarization by spin-on. In the embodiment, material of this layer is preferably SiLK. The second dielectric layer  208  is typically deposited to a thickness of about 2500 angstroms. The second cap layer  210  comprises silicon nitride (SiN) or silicon carbide (SiC). A first hardmask layer  212  is formed over the second cap layer  210 . The first hardmask layer  212  comprises trieothoxysilane (TEOS). Then, a first bottom anti-reflective coating (BARC) layer  214  is formed on the second cap layer  210 . A first photoresist layer  216  is deposited on the first bottom anti-reflective coating (BARC) layer  214 . The first photoresist layer  216  has a trench opening  217  by using conventional lithographic technology. Then, the first bottom anti-reflective coating (BARC) layer  214  is etch by using the first photoresist layer  216  as a mask.  
         [0029]    Referring to FIG. 2B, the first hardmask layer  212  has a trench opening  217   a  by using conventional lithographic technology. Then, the second cap layer  210  is etch by using the first hardmask layer  212  as a mask. Then, the trench opening  217   a  is formed by anisotropically etching method. A first photoresist layer  216  is then removed. Then, the bottom anti-reflective coating (BARC) layer  214  is also removed at the same time.  
         [0030]    Referring to FIG. 2C, a dielectric layer  218  is formed on the second dielectric layer  208  and filled in the trench opening  217   a  by spin-on. The dielectric layer  218  is a low-k dielectric material. A second hardmask layer  220  is formed over the SiLK layer  218 . The second hardmask layer  220  comprises TiN. Then, a second bottom anti-reflective coating (BARC) layer  222  is formed on the second hardmask layer  220 . A second photoresist layer  224  is deposited on the second bottom anti-reflective coating (BARC) layer  222 . The second photoresist layer  224  has a via opening  225   a  by using conventional lithographic technology. Then, the bottom anti-reflective coating (BARC) layer  222 , the second hardmask layer  220 , the dielectric layer  218 , the second dielectric layer  208  and the first dielectric layer  206  are etch by using econd photoresist layer  224  as a mask.  
         [0031]    Referring to FIG. 2D, the via opening  225   a  is formed by dry etching method. Then, a second photoresist layer  224  is removed. Then, the second bottom anti-reflective coating (BARC) layer  222  is also removed at the same time. The use of CxHyFz (such as CHF 3 ), O 2 , and argon as etchants for the second hardmask layer  220  and the second cap layer  210 . The second hardmask layer  220  and a portion of the dielectric layer  218  are removed because the etch selectivity of the dielectric layer  218  is different from the second hardmask layer  220 . The portion of the dielectric layer  218  is removed become a dielectric layer  218   a . Then, the second dielectric layer  208  is used of N 2 /H 2  as etchants and the first dielectric layer  206  is used of N 2 , C 4 F 8  and Argon as etchants. Then, the dielectric layer  218   a , the sidewall of the second cap layer  210  and the second dielectric layer  208  are etched on the first dielectric layer  206 . The etch step is through first cap layer  204  stopping on the metal layer  202 .  
         [0032]    Referring to FIG. 2E, a trench opening  227  is formed on the first dielectric layer  206 . The trench opening  227  is formed by anisotropically etching method. Then, the first dielectric layer  206  having a via opening  225   b , wherein the trench opening  227  is over the via opening  225   b . Finally, the metal layer  202  is cleaned surface by in-situ.  
         [0033]    The method for forming hybrid low-k film stack to avoid thermal stress effect using the above explained method, has the following advantages:  
         [0034]    1. The present invention is to provide a method for forming hybrid low-k film stack to avoid thermal stress effect that means combination both SiLK of organic spin-on low-k material and Coral of chemical vapor deposition low-k material to decrease thermal stress effect.  
         [0035]    2. The present invention is to provide a method for forming hybrid low-k film stack to avoid thermal stress effect that means combination both SiLK of organic spin-on low-k material and Coral of chemical vapor deposition low-k material to apply below 0.13 micron process.  
         [0036]    Although a specific embodiment have been illustrated and described, it will be obvious to those skilled in the art that various modifications may be made without departing from what is intended to be limited solely by the appended claims.