Abstract:
A method for removing defects due to edge chips of a semiconductor wafer is disclosed. This method includes forming a molding layer over a semiconductor wafer. The molding layer is patterned to form a plurality of storage node holes, where the plurality of storage node holes include at least one first storage node hole formed on an effective chip area and at least one second storage node hole formed on an edge chip area. First storage nodes and second storage nodes are formed in the first and second storage node holes, respectively. A photoresist pattern is formed on the wafer having the storage nodes. The photoresist pattern is preferably formed to expose the effective chip areas and to cover the edge chip areas. The molding layer is etched, using the photoresist pattern as an etching mask, to expose portions of the first storage nodes.

Description:
This patent application is a divisional of U.S. patent application Ser. No. 10/809,076 filed on Mar. 24, 2004, now pending, and claims priority from Korean Patent Application No. 2003-18274, filed on Mar. 24, 2003, the contents of which are hereby incorporated by reference in their entirety. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to a process for manufacturing a semiconductor device and, more particularly, to a semiconductor process for removing defects due to edge chips of a semiconductor wafer and semiconductor device fabricated thereby. 
   2. Description of the Related Art 
   Most semiconductor chips are formed in a circle-shaped semiconductor wafer. Therefore, the semiconductor chips located at the edge of the semiconductor wafer may have abnormal patterns. This is due to a defocus or the like that occurs during a photolithography process for forming predetermined patterns in the edge of the semiconductor wafer. 
     FIGS. 1 through 6  are cross-sectional views illustrating a conventional semiconductor process for forming DRAM devices on a semiconductor wafer. In the drawings, reference characters “A” and “B” represent a main chip area formed in an inside region of the semiconductor wafer and an edge chip area formed in an edge of the semiconductor wafer, respectively. 
   Referring to  FIG. 1 , an interlayer dielectric layer  3  and an etch stop layer  7  are sequentially formed on a semiconductor wafer  1 . The etch stop layer  7  and the interlayer dielectric layer  3  are patterned to form main chip buried contact holes in the main chip area A and edge chip buried contact holes in the edge chip area B. Main chip buried contact plugs  5   a  and edge chip buried contact plugs  5   b  are formed in the main chip buried contact holes and in the edge chip buried contact holes, respectively. A molding layer such as a molding oxide layer  9  is formed on an entire surface of the semiconductor wafer  1  having the buried contact plugs  5   a  and  5   b . A photoresist layer  11  is coated on the molding oxide layer  9 . As illustrated in  FIG. 1 , the photoresist layer  11  has a non-uniform thickness throughout the wafer  1 . In other words, the photoresist layer over the edge region of the wafer  1  may be formed to be thicker than the photoresist layer over the inside region of the wafer  1 . 
   Subsequently, the photoresist layer  11  over the edge of the wafer  1  is selectively exposed and removed to expose the molding oxide layer  9  in the edge of the wafer  1 . The edge exposure process is for preventing a clamp that contacts with the edge of the wafer from being contaminated by the photoresist layer during a subsequent dry etching process. The exposed edge molding oxide layer has a width of We. Preferably, the width We is minimized to increase the number of effective chips formed at the wafer  1 . Therefore, although the photoresist layer  11  over the edge of the wafer  1  is selectively removed, the remaining photoresist layer  11  over the wafer  1  may be still non uniform. 
   The remaining photoresist layer is then exposed and developed using a storage node mask. Consequently, first storage node openings  11   a  and second storage node openings  11   b  are formed in the main chip area A and in the edge chip area B respectively. The first storage node openings  11   a  exhibit normal profiles that expose the molding oxide layer  9  in the main chip area A, whereas the second storage node openings  11   b  exhibit abnormal profiles that do not expose the molding oxide layer  9  in the edge chip area B. This phenomenon is due to the uneven thickness of the photoresist layer as described above. In other words, the exposure process with the storage node mask is performed within a predetermined focus latitude that is suitable for the uniform thickness of the photoresist layer  11  in the main chip area A. Accordingly, it is difficult to optimize the focus latitude of light irradiated onto the edge chip area B. As a result, defocus occurs in the edge chip area B and the second storage node openings  11   b  show abnormal profiles. In addition, the defocus phenomenon in the edge chip area B may be due to the uneven surface profiles on the edge of the wafer  1 , especially, on a bevel region of the wafer  1 . 
   Referring to  FIG. 2 , the molding oxide layer  9  and the etch stop layer  7  are etched using the photoresist layer  11  having the first storage node openings  11   a  and the second storage node openings  11   b  as an etch mask. As a result, first storage node holes  13   a  exposing the main chip buried contact plugs  5   a  are formed in the main chip area A. However, second storage node holes  13   b  having abnormal profiles are formed in the edge chip area B. As shown in  FIG. 2 , the second storage node holes  13   b  do not expose the edge chip buried contact plugs  5   b . This is due to the abnormal profiles of the second storage node openings  11   b . The photoresist layer  11  is then removed. 
   Referring to  FIG. 3 , a polysilicon layer and a sacrificial layer formed of a material such as oxide are sequentially formed on an entire surface of the semiconductor wafer  1  having the first and second storage node holes  13   a  and  13   b . The polysilicon layer is conformally formed, and the sacrificial oxide layer is formed to a sufficient thickness to fill the first and second storage node holes  13   a  and  13   b . The polysilicon layer and the sacrificial oxide layer are etched back until a top surface of the molding oxide layer  9  is exposed. As a result, first cylindrical storage nodes  15   a  are respectively formed in the first storage node holes  13   a , and second cylindrical storage nodes  15   b  are respectively formed in the second storage node holes  13   b . Further, sacrificial oxide layer patterns  17  remain in the first and second storage nodes  15   a  and  15   b . As shown in  FIG. 3 , the second storage nodes  15   b  adjacent to the edge of the wafer  1  are not in contact with the edge chip buried contact plugs  5   b.    
   Referring to  FIG. 4 , the molding oxide layer  9  and the sacrificial oxide layer patterns  17  are removed using a wet etching process. Accordingly, inner walls and outer sidewalls of the first and second storage nodes  15   a  and  15   b  are exposed. The second storage nodes  15   b  adjacent to the edge of the wafer  1  may be lifted during the wet etching process for removing the molding oxide layer  9  and the sacrificial oxide layer patterns  17 . The second storage nodes  15   b , which are lifted from the surface of the wafer, are adhered onto the surface of the main chip area A, thereby acting as particle sources. 
   Referring to  FIG. 5 , a dielectric layer  19  and a plate conductive layer are sequentially formed over the semiconductor wafer  1  where the molding oxide layer  9  and the sacrificial oxide layer patterns  17  are removed. The plate conductive layer and the dielectric layer  19  are patterned to form a first plate electrode  21   a  and a second plate electrode  21   b  that cover a cell array area in the main chip area A and a cell array area in the edge chip area B, respectively. Consequently, as shown in  FIG. 5 , the cell array area adjacent to the edge of the wafer  1  has a relatively low surface profile as compared to a normal cell array area (cell array area in the main chip area A). In other words, there exists a step difference H between a top surface of the plate electrode ( 21   a  of  FIG. 5 ) in the normal cell array area and a top surface of the plate electrode ( 21   b  of  FIG. 5 ) in the abnormal cell array area. An upper interlayer dielectric layer  23  is formed over the semiconductor wafer having the first plate electrode  21   a  and the second plate electrode  21   b . The upper interlayer dielectric layer  23  is generally formed of a flowable oxide layer such as a BPSG (boro-phosphor-silicate glass) layer. Nevertheless, the upper interlayer dielectric layer  23  also has an uneven surface profile, which is due to the step difference H. 
   Referring to  FIG. 6 , the uneven surface profile of the upper interlayer dielectric layer  23  may lead to a difficulty in a subsequent photolithography process. Accordingly, there is a need to planarize the upper interlayer dielectric layer  23  using a planarization process such as a chemical mechanical polishing (hereinafter, referred to as “CMP”) process. However, when the upper interlayer dielectric layer  23  having the uneven surface is planarized using the CMP process, an upper corner C of the plate electrode in the normal cell array area adjacent to the abnormal cell array area may be exposed as shown in  FIG. 6 . 
   As discussed above, the storage nodes in the cell array area that is adjacent to the edge of the wafer may be lifted during a subsequent wet etching process. The storage nodes, which are lifted, are adhered onto the normal main chip area, thereby acting as particle sources. 
   Accordingly, the manufacturing yield of semiconductor devices is significantly reduced. Moreover, the abnormal area where the storage nodes are lifted has a lower surface than the normal cell array area. Thus, the storage nodes in the normal cell array area may be exposed during a subsequent planarization process. 
   SUMMARY OF THE INVENTION 
   The semiconductor processes include forming a molding layer on a semiconductor wafer. The molding layer is patterned to form first storage node holes and second storage node holes. The first storage node holes are formed in a plurality of effective chip areas which are defined in an inside area of the wafer, and the second storage node holes are formed in a plurality of edge chip areas which are defined in an edge of the wafer. First and second storage nodes are formed in the first and second storage node holes respectively. A photoresist pattern is formed on a predetermined area of the wafer having the storage nodes. The photoresist pattern covers portions of the edge chip areas. The molding layer in the effective chip areas is selectively etched using the photoresist pattern as an etching mask, thereby exposing portions of the first storage nodes. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIGS. 1 through 6  are cross-sectional views for illustrating a conventional semiconductor process. 
       FIG. 7  is a top plan view for illustrating semiconductor processes according to embodiments of this disclosure. 
       FIGS. 8 through 12  are cross-sectional views, taken along the line I-I′ of  FIG. 7 , to illustrate semiconductor processes according to embodiments of this disclosure. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   This disclosure will now describe embodiments of the invention more fully hereinafter with reference to the accompanying drawings.  FIG. 7  is a top plan view to illustrate processes of fabricating semiconductor chips formed on a semiconductor wafer in accordance with embodiments of this disclosure, and  FIGS. 8 through 12  are cross-sectional views taken along the line I-I′ of  FIG. 7 . In the drawings, reference characters “A” and “B” indicate effective chip areas formed in the inside of the semiconductor wafer and the edge chip areas formed in the edge of the semiconductor wafer, respectively. Furthermore, each of the effective chip areas A comprises an effective cell array area Cm and an effective peripheral circuit area Pm surrounding the effective cell array area Cm, and each of the edge chip areas B comprises an edge cell array area Ce and an edge peripheral circuit area Pe surrounding the edge cell array area Ce. Scribe lanes S/L are interposed between the chip areas A and B. 
   Referring to  FIGS. 7 and 8 , a lower interlayer dielectric layer  53  and an etch stop layer  57  are sequentially formed on the semiconductor wafer  51 . It is preferable that the lower interlayer dielectric layer  53  is formed of a silicon oxide layer and the etch stop layer  57  is formed of a material layer having an etch selectivity with respect to the lower interlayer dielectric layer  53 . For example, the etch stop layer  57  may be formed of a silicon nitride layer. The etch stop layer  57  and the lower interlayer dielectric layer  53  are patterned to form buried contact holes in the respective cell array areas Cm and Ce. The buried contact holes expose predetermined areas of the semiconductor wafer  1 . When semiconductor devices formed in the chip areas A and B are DRAM devices, the buried contact holes expose source areas of access transistors in the DRAM cells. Buried contact plugs are formed in the buried contact holes. The buried contact plugs comprise first buried contact plugs  55   a  formed in the effective cell array areas Cm and second buried contact plugs  55   b  formed in the edge cell array areas Ce. 
   A molding layer such as a molding oxide layer  59  is formed on the semiconductor wafer  51  having the buried contact plugs  55   a  and  55   b . The molding oxide layer  59  is preferably formed of a material layer having an etch selectivity with respect to the etch stop layer  57 . For example, the molding oxide layer  59  may be formed of a chemical vapor deposition (CVD) oxide layer. A first photoresist layer  61  is coated on the molding oxide layer  59 . The first photoresist layer  61  generally has an uneven thickness throughout the wafer  51 . In detail, the first photoresist layer  61  on the edge of the wafer  51  may be thicker than the first photoresist layer  61  on the inside region of the wafer  51 . The photoresist layer  61  on the edge of the wafer  51  is selectively exposed and developed to expose the edge of the molding oxide layer  59 . The edge exposure area has a first width of W 1 . It is desirable that the first width W 1  has a minimum value within an allowed range in order to increase the number of the effective chip areas A. Removing the first photoresist layer  61  on the edge of the wafer  51  is for preventing a clamp which fixes the wafer  51  during a subsequent dry etching process from being contaminated by the photoresist layer  61 . Nevertheless, the first photoresist layer  61  adjacent to the edge exposure area may be still thicker than the first photoresist layer  61  in the inside region of the wafer  51 . 
   The first photoresist layer  61  that remains after the edge exposure process is patterned using a storage node mask to form storage node openings. The storage node openings comprise first storage node openings  61   a  formed in the effective cell array areas Cm and second storage node openings  61   b  formed in the edge cell array areas Ce. In this case, the first storage node openings  61   a  exhibit a normal profile that exposes the molding oxide layer  59 , whereas the second node openings  61   b , especially, the second node openings  61   b  adjacent to the edge exposure area, exhibit an abnormal profile that does not expose the molding oxide layer  59 . This is due to a defocus that is caused by a non-uniform thickness of the first photoresist layer  61 . In addition, the defocus may also be due to the uneven surface profile of the edge of the wafer  51 , that is, a bevel region of the wafer  51 . 
   Referring to  FIGS. 7 and 9 , the molding oxide layer  59  and the etch stop layer  57  are etched using the photoresist layer  61  having the first and second storage node openings  61   a  and  61   b  as an etch mask, thereby forming first and second storage node holes  63   a  and  63   b  in the effective cell array areas Cm and in the edge cell array areas Ce, respectively. The first storage node holes  63   a  may show a normal profile that exposes the first buried contact plugs  55   a , whereas the second storage node holes  63   b  may show an abnormal profile that does not expose the second buried contact plugs  55   b , as illustrated in  FIG. 9 . The first photoresist layer  61  is then removed. 
   Referring to  FIGS. 7 and 10 , a storage node conductive layer is conformally formed on a surface of the wafer having the first and second storage node holes  63   a  and  63   b . The storage node conductive layer may comprise a doped polysilicon layer. Subsequently, a sacrificial oxide layer that fills the first and second storage node holes  63   a  and  63   b  is formed on the storage node conductive layer. The sacrificial oxide layer and the storage node conductive layer are etched back until a top surface of the molding oxide layer  59  is exposed, thereby forming a first cylindrical storage nodes  65   a  in the first storage node holes  63   a  and a second cylindrical storage nodes  65   b  in the second storage node holes  63   b . As a result, sacrificial layer patterns  67  may remain in the first and second cylindrical storage nodes  65   a  and  65   b.    
   Alternatively, the storage node conductive layer may be formed to completely fill the first and second storage node holes  63   a  and  63   b . In this case, the formation process of the sacrificial oxide layer is omitted, and first and second box-shaped storage nodes are formed in the first and second storage node holes  63   a  and  63   b , respectively. 
   The first storage nodes  65   a  are normally formed to be in contact with the first buried contact plugs  55   a . On the contrary, the second storage nodes  65   b  may be spaced apart from the second buried contact plugs  55   b  by the molding oxide layer  59 , as shown in  FIG. 10 . 
   A second photoresist layer is formed on the semiconductor wafer having the first and second storage nodes  65   a  and  65   b . The second photoresist layer is patterned using a blank mask to form a second photoresist pattern  69  that only exposes the effective chip area A. As a result, the second photoresist pattern  69  covers the edge chip area B. Further, the second photoresist pattern  69  may expose the scribe lane S/L. Prior to formation of the second photoresist pattern  69 , the edge region of the second photoresist layer may be selectively exposed and developed to form a second edge exposure area having a second width of W 2 . In this case, it is preferable that the second width W 2  is smaller than the first width W 1 . 
   Referring to  FIGS. 7 and 11 , the molding oxide layer  59  and the sacrificial oxide layer patterns  67 , in the effective chip area A, are selectively etched using the second photoresist pattern  69  as an etch mask, thereby exposing inner walls and outer sidewalls of the first storage nodes  65   a . The molding oxide layer  59  and the sacrificial layer patterns  67  may be etched using a wet etching technique. The molding oxide layer  59  and the sacrificial oxide layer patterns  67  in the edge chip areas B are not etched because of the presence of the second photoresist pattern  69 . Accordingly, the second photoresist pattern  69  prevents the second storage nodes  65   b  from being lifted. In addition, the surface of the edge chip area B has the same level as the top surfaces of the first storage nodes  65   a  in the effective chip area A. The second photoresist pattern  69  is then removed, preferably by using an ashing process. 
   A dielectric layer and a plate conductive layer are sequentially formed on the wafer  1 , in which the second photoresist pattern  69  is removed. The plate conductive layer and the dielectric layer are patterned to form dielectric layer patterns  71  and plate electrodes  73 , which are sequentially stacked. The dielectric layer patterns  71  and the plate electrodes  73  are formed to cover the effective cell array areas Cm and the edge cell array areas Ce. Therefore, the top surfaces of the plate electrodes  73  in the effective cell array areas Cm and the edge cell array areas Ce may be located at the same level. A first upper interlayer dielectric layer is formed on the wafer having the plate electrodes  73 . The first upper interlayer dielectric layer may be formed of a flowable dielectric layer such as a BPSG layer. The surface of the first upper interlayer dielectric layer may still have an uneven profile. This is due to the first storage nodes  65   a  in the effective cell array areas Cm and the un-etched molding oxide layer  59  in the edge cell array areas Ce. Thus, the first upper interlayer dielectric layer in the cell array areas Cm and Ce is selectively and partially etched to form a first planarized upper interlayer dielectric layer  75 . Nevertheless, the first planarized upper interlayer dielectric layer  75  may still have a global step difference. 
   Referring to  FIGS. 7 and 12 , a second upper interlayer dielectric layer is formed on the first planarized upper interlayer dielectric layer  75 . The second upper interlayer dielectric layer may be formed of a CVD oxide layer. The second upper interlayer dielectric layer and the first planarized upper interlayer dielectric layer  75  are planarized using a CMP process to form a fully planarized upper interlayer dielectric layer  77 . As a result, the top surface of the fully planarized upper interlayer dielectric layer  77  shows a flat profile throughout the wafer  51 . Accordingly, when a metal layer is formed on the fully planarized upper interlayer dielectric layer  77  and the metal layer is patterned using a photolithography process, the flat top surface of the upper interlayer dielectric layer  77  can prevent a process margin from being reduced by a defocus or an irregular reflection. 
   As described above, the edge chip areas adjacent to the edge of the wafer are covered with a photoresist pattern during the etching process for exposing sidewalls of the first storage nodes in the effective chip areas. As a result, the photoresist pattern can prevent the second storage nodes in the edge chip areas from being lifted, even though the second storage nodes are spaced apart from the second buried contact plugs. 
   While the invention has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense. Indeed, it should be readily apparent to those skilled in the art in view that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.