Abstract:
A first insulating film is formed on an underlying substrate, the first insulating film being made of a first insulating material. A second insulating film is formed on the first insulating film, the second insulating film being made of a second insulating material different from the first insulating material. A trench is formed through the second and first insulating film, the trench reaching at least an intermediate depth of the first insulating film. A wiring layer made of a conductive material is deposited on the second insulating film, the wiring layer burying the trench. The wiring layer is polished to leave the wiring layer in the trench. The wiring layer and second insulating film are polished until the first insulating film is exposed. Irregularity such as dishing and erosion can be suppressed from being formed.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is based on Japanese Patent Application No. 2002-166621, filed on Jun. 7, 2002, the entire contents of which are incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     A) Field of the Invention 
     The present invention relates to a wiring pattern forming method, and more particularly to a wiring pattern forming method of forming a trench through an insulating layer, depositing a conductive material on the insulating layer to bury the trench with the conductive material, and polishing the conductive material to leave a portion of the conductive material in the trench. 
     B) Description of the Related Art 
     A damascene method, which is compatible with both high speed and reliability, is used in the wiring pattern forming process for a high density semiconductor integrated circuit device. A dual damascene method is essential for the manufacture of sophisticated semiconductor integrated circuit devices, which method forms trenches and via holes for a wiring pattern thorough an interlayer insulating film, buries the trenches and via holes with copper and removes an unnecessary portion of the copper by chemical mechanical polishing. 
     With reference to FIGS. 5A to  5 D, a wiring layer forming method using a conventional dual damascene method will be described. 
     As shown in FIG. 5A, a copper wiring layer  101  is disposed in the partial area of a surface layer of an underlying interlayer insulating film  100 . On the interlayer insulating film  100  and wiring layer  101 , a cap layer  102 , a first interlayer insulating film  103 , an etching stopper layer  104  and a second interlayer insulating film  105  are sequentially deposited. A wiring trench  106  is formed through the second interlayer insulating film  105  by an ordinary photolithography process. The etching stopper layer  104  is therefore exposed on the bottom of the wiring trench  106 . 
     As shown in FIG. 5B, an opening is formed through the etching stopper layer  104  exposed on the bottom of the wiring trench  106  by using ordinary photolithography techniques. The first interlayer insulating film  103  is etched via the opening to form a via hole  107 . The cap layer  102  exposed on the bottom of the via hole  107  is removed to expose the copper wiring layer  101 . 
     A barrier metal layer is formed on the inner surfaces of the wiring trench  106  and via hole  107 , and a copper seed layer is formed on the barrier metal layer. Copper is electroplated by using the seed layer as an electrode to form a copper layer  108 . The copper layer  108  is filled in the wiring trench  106  and via hole  107 . 
     As shown in FIG. 5C, the copper layer  108  is subjected to chemical mechanical polishing (CMP) to remove an unnecessary portion of the copper layer  108 . The copper wiring layer  108  is therefore left in the wiring trench  106  and via hole  107 . 
     As shown in FIG. 5D, on the second interlayer insulating film  105  and copper wiring layer  108 , a cap layer  109  and a third interlayer insulating film  110  are formed. On this wiring layer  108 , an upper level wiring layer is formed by a method similar to that used for forming the wiring layer  108 . 
     As CMP of the copper wiring layer  108  is performed at the process shown in FIG. 5C, irregularity called dishing and erosion is formed on the surface of the substrate. 
     FIG. 6A shows the measurement results of irregularity on a substrate surface after CMP. The abscissa represents a scan distance along the substrate surface and one gradation corresponds to 80 μm. The ordinate represents a surface height and one gradation corresponds to 50 nm. Dishing D is formed at positions corresponding to the copper wiring pattern. Erosion E is formed in the area where copper wires are dense. 
     Dishing is formed because a polishing pad used for CMP deforms and the motion of the polishing pad follows the wiring pattern. Erosion is formed because a work pressure of CMP is concentrated upon an insulating film separating copper wires so that the insulating film and copper wires are polished excessively. 
     FIG. 6B shows the relation between a dishing depth and a wiring width. The abscissa represents a wiring width in the unit of “μm” and the ordinate represents a dishing depth in the unit of “nm”. It can be seen that as the wiring width becomes broader, the dishing becomes deeper. 
     If dishing and erosion are formed, the surface of the third interlayer insulating film  110  shown in FIG. 5D has irregularity in conformity with the surface irregularity of the underlying layer. Irregularity formed on the surface of an interlayer insulating film may generate copper polishing residues as the copper layer buried in the wiring trench formed through the interlayer insulating film is polished. The copper polished residues may cause a short circuit of wiring lines. In order to prevent the generation of copper polishing residues, it is necessary to planarize the surface of an interlayer insulating film by CMP or the like after it is formed. 
     SUMMARY OF THE INVENTION 
     It is an object of the invention to provide a wiring pattern forming method capable of suppressing the formation of irregularity such as dishing and erosion. 
     According to one aspect of the present invention, there is provided a method of forming a wiring layer, comprising the steps of: (a) forming a first insulating film on an underlying substrate, the first insulating film comprising a first insulating material; (b) forming a second insulating film on the first insulating film, the second insulating film comprising a second insulating material different from the first insulating material; (c) forming a trench through the second and first insulating films, the trench reaching at least an intermediate depth of the first insulating film; (d) depositing a wiring layer comprising a conductive material on the second insulating film, the wiring layer burying the trench; (e) polishing the wiring layer to leave the wiring layer in the trench; and (f polishing the wiring layer and the second insulating film until the first insulating film is exposed. 
     By properly selecting the polishing conditions of the step (f, the formation of dishing and erosion can be suppressed. 
     As above, irregularity of a substrate surface after chemical mechanical polishing can be reduced. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross sectional view of a semiconductor integrated circuit device manufactured by a wiring pattern forming method according to a first embodiment of the invention. 
     FIGS. 2A to  2 G are cross sectional views of a wiring pattern illustrating the wiring pattern forming method of the first embodiment. 
     FIGS. 3A and 3B are graphs showing the relation between a dishing depth and a wiring width after chemical mechanical polishing. 
     FIGS. 4A to  4 G are cross sectional views of a wiring pattern illustrating a wiring pattern forming method according to a second embodiment of the invention. 
     FIGS. 5A to  5 D are cross sectional views of wiring layers illustrating a wiring layer forming method adopting a conventional dual damascene method. 
     FIG. 6A is a graph showing irregularity on a substrate surface after chemical mechanical polishing, and FIG. 6B is a graph showing the relation between a dishing depth and a wiring width. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 is a cross sectional view of a semiconductor integrated circuit device manufactured by a wiring pattern forming method according to the first embodiment of the invention. A semiconductor substrate  1  made of p-type silicon has an element separation insulating film  2  formed in the surface layer of the substrate. The element separation insulating film  2  defines active regions. A MOS transistor  3  is formed in the active region. The MOS transistor  3  has a gate insulating film  3   a , a gate electrode  3   b  and impurity diffusion regions  3   c  and  3   d . One of the impurity diffusion regions  3   c  and  3   d  is a source region and the other is a drain region. 
     The impurity diffusion regions  3   c  and  3   d  formed in the surface layer on both sides of the gate electrode  3   b  have a lightly doped drain (LDD) structure. The gate electrode  3   b  has insulating side wall spacers  3   e  formed on the side walls of the gate electrode  3   b . The side wall spacers  3   e  are used as the mask when ions are implanted into the high impurity concentration areas of the impurity diffusion regions  3   c  and  3   d.    
     A first interlayer insulating film  4  made of silicon oxide (SiO 2 ) is formed on the semiconductor substrate  1 , covering the MOS transistor  3 . The first interlayer insulating film  4  has contact holes  4   a  and  4   b  formed therethrough at positions corresponding to the impurity diffusion regions  3   c  and  3   d . Conductive plugs  5   a  and  5   b  are buried in the contact holes  4   a  and  4   b . Each of the plugs  5   a  and  5   b  is constituted of a barrier metal layer made of titanium nitride (TiN) and covering the side and bottom walls of the plug and a tungsten member formed on the barrier metal layer. 
     A first wiring layer  7  made of aluminum is formed on the first interlayer insulating film  4 . This wiring layer  7  is connected to the impurity diffusion region  3   d  of the MOS transistor  3  via the plug  5   b.    
     A second interlayer insulating film  8  formed on the first interlayer insulating film  4  covers the first wiring layer  7 . The second interlayer insulating film  8  is made of silicon oxide, borophosphosilicate glass (BPSG) or phosphosilicate glass (PSG). The second interlayer insulating film  8  has a contact hole  8   a  formed therethrough at the position corresponding to the plug  5   a . A conductive plug  9  is buried in the contact hole  8   a.    
     Formed on the second interlayer insulating film  8  are a cap layer  10  made of silicon nitride and a third interlayer insulating film  11  made of silicon oxide. The third interlayer insulating film  11  and cap layer  10  have wiring trenches  11   a  and  11   b  formed therethrough. Second layer wiring layers  12   a  and  12   b  are buried in the wiring trenches  11   a  and  11   b.    
     Each of the wiring layers  12   a  and  12   b  has a three-layer structure including: a barrier metal layer covering the side and bottom walls of a corresponding one of the wiring trenches  11   a  and  11   b ; a seed layer covering the barrier metal layer; and a main wiring member filled in the wiring trench and covering the seed layer. The barrier metal layer is made of tantalum (Ta), tantalum nitride (TaN), titanium nitride (TiN) or the like. The barrier metal layer may have a lamination structure of a Ta layer and a TaN layer. The seed layer and main wiring member are made of copper or alloy mainly containing copper. 
     A cap layer  15 , a fourth interlayer insulating film  16 , an etching stopper layer  17  and a fifth interlayer insulating film  18  are formed in this order on the wiring layers  12   a  and  12   b  and third interlayer insulating film  11 . The etching stopper layers  15  and  17  are made of silicon carbide (SiC). The fourth and fifth interlayer insulating films  16  and  18  are made of SiOC. 
     The fifth interlayer insulating film  18  has a wiring trench  19  reaching the etching stopper layer  17 . A via hole  20  is formed extending from the etching stopper layer  17  on the bottom of the wiring trench  19  to the upper surface of the wiring layer  12   a.    
     A third layer wiring layer  21  is buried in the wiring trench  19  and via hole  20 . The third layer wiring layer  21  is constituted of: a barrier metal layer covering the side and bottom walls of the wiring trench  10  and via hole; a seed layer covering the barrier metal layer; and a main wiring member filled in the wiring trench  19  and via hole  10  and covering the seed layer. The materials of the barrier metal layer, seed layer and main wiring member are similar to those of the second layer wiring layer  12   a.    
     Next, with reference to FIGS. 2A to  2 G, the wiring pattern forming method of the first embodiment will be described by taking as an example the method of forming the third layer wiring layer  21  shown in FIG.  1 . FIGS. 2A to  2 G show only the cap layer  15  shown in FIG.  1  and layers at higher levels. 
     As shown in FIG. 2A, on the third interlayer insulating film  11 , the cap layer  15  of SiC having a thickness of 50 nm, the fourth interlayer insulating film  16  of SiOC having a thickness of 600 nm, the etching stopper layer  17  of SiC having a thickness of 50 nm, the fifth interlayer insulating film  18  of SiOC having a thickness of 400 nm, and a sacrificial film  30  of SiO 2  having a thickness of 100 nm are sequentially formed. These layers and films can be formed by plasma enhanced chemical vapor deposition (PE-CVD). The SiC film and SiOC film may be made of materials under the product names SiC or CORAL of Novellus Systems, Inc., or BLOCK or BlackDiamond of Applied Materials, Inc. 
     If necessary, an antireflection film of SiON, SiN or the like may be formed on the sacrificial film  30 . 
     As shown in FIG. 2B, the surface of the sacrificial film  30  is covered with a resist film  31  and openings corresponding to a wiring pattern are formed through the resist film  31 . By using the resist film  31  as a mask, the sacrificial film  30  and fifth interlayer insulating film  18  are dry-etched to form wiring trenches  19 . For example, etching gas may be mixed gas of CF 4  and CH 2 F 2 , C 4 F 6  gas or the like. Etching stops when the etching stopper layer  17  is exposed. After the wiring trenches  19  are formed, the resist film  31  is removed. 
     As shown in FIG. 2C, the upper surface of the sacrificial film  30  and the inner surfaces of the wiring trenches  19  are covered with a resist film  32 . Openings corresponding to via holes to be formed are formed through the resist film  32 . By using the resist film  32  as a mask, the etching stopper layer  17  and fourth interlayer insulating film  16  are etched. For example, the etching stopper layer  17  is dry-etched by using mixed gas of CF 4  and CH 2 F 2 , and the fourth interlayer insulating film  16  is dry-etched by using C 4 F 6  gas. Via holes  20  are therefore formed and the cap layer  15  is exposed on the bottom surfaces of the via holes  20 . After the fourth interlayer insulating film  16  is etched, the resist film  32  is removed. 
     The cap layer  15  exposed on the bottom surfaces of the via holes  20  is removed to expose underlying copper wiring layers. For example, the cap layer  15  is dry-etched by using CHF 3  gas. At this time, the etching stopper layer  17  exposed on the bottom surfaces of the wiring trenches  19  is removed. 
     As shown in FIG. 2D, the inner surfaces of the wiring trenches  19  and via holes  20  and the upper surface of the sacrificial film  30  are covered with a barrier metal layer  21   a  of tantalum having a thickness of 10 nm. The material of the barrier metal layer  21  a may be tantalum nitride (TaN), titanium nitride (TiN) or the like. On the surface of the barrier metal layer  21   a , a seed layer  21   b  of copper (Cu) having a thickness of 150 nm is formed. The barrier metal layer  21   a  and seed layer  21   b  are formed by sputtering. Next, copper is electroplated to form a copper layer  21   c . The copper layer  21   c  has a thickness sufficient for being filled in the wiring trenches  19  and via holes  20 . 
     As shown in FIG. 2E, the copper layer  21   c  is subjected to chemical mechanical polishing by using the polishing liquid with which the polishing speed of copper becomes faster than that of tantalum or silicon oxide. The polishing liquid to be used contains, for example, abrasive grains of silica or the like, organic substance forming complex with copper, copper anticorrosion agent, oxidant and the like. Since the polishing speed of tantalum and silicon oxide is relatively slow, polishing can be stopped with high reproductivity when the barrier metal layer  21   a  of Ta or the sacrificial film  30  of SiO 2  is exposed. 
     Since the polishing speed of copper is relatively fast, dishing is formed on the surface of the copper wiring layer  21   c  left in the wiring trench  19 . It is preferable to make the sacrificial film 30 thick in order to make the deepest position of the dishing becomes higher than the bottom of the sacrificial film  30 . 
     As shown in FIG. 2F, the sacrificial film  30 , copper layer  21   c , seed layer  21   b  and barrier metal layer  21   a  are subjected to chemical mechanical polishing by using the polishing liquid with which the polishing speed of tantalum or silicon oxide becomes faster than that of copper. The polishing liquid to be used may contain, for example, abrasive grains of silica or the like, organic acid, copper anticorrosion agent. 
     As polishing the barrier metal layer  21   b  of tantalum and the sacrificial film  30  of SiO 2  advances, the dishing on the surface of the copper layer  21   c  shown in FIG. 2E is planarized. As polishing advances further, the exposed surface of the copper layer  21   c  protrudes. Since a polishing pressure is concentrated upon this protruded region, the surface of the copper layer  21   c  is eventually planarized. 
     As shown in FIG. 2G, when the fifth interlayer insulating film  18  made of hydrophobic SiOC is exposed, polishing can be stopped with high reproductivity because the fifth interlayer insulating film  18  functions as a polishing stopper layer. Under the polishing conditions of a relatively low polishing speed of copper, dishing is hard to be formed on the surface of the copper layer  21   c . The formation of erosion can also be prevented. 
     FIGS. 3A and 3B are graphs showing the relation between a depth of a dent formed on a substrate surface and a wiring width. FIG. 3A shows dent depths when the wiring pattern forming method of the first embodiment is used, and FIG. 3B shows dent depths when the conventional wiring pattern forming method is used. The abscissa represents a wiring width in the unit of “μm” and the ordinate represents a dent depth from a virtual flat surface in the unit of “nm”. The area of a wiring pattern was 80% of the whole substrate surface. 
     It can be seen from the comparison between FIGS. 3A and 3B that the dent is shallow when the wiring pattern forming method of the first embodiment is used. By adopting the wiring pattern forming method of the first embodiment, the substrate surface after CMP can be planarized sufficiently. 
     In the first embodiment, the fourth and fifth interlayer insulating films  16  and  18  are made of SiOC having a dielectric constant lower than SiO 2 . A parasitic capacitance between wiring lines can therefore be reduced. 
     A thin cap layer of SiC may be disposed between the fifth interlayer insulating film  18  and sacrificial film  30  shown in FIG.  2 A. For example, the thickness of the cap layer is about 30 to 50 nm. In the state after CMP shown in FIG. 2G, the thin cap layer of SiC is left on the surface of the fifth interlayer insulating film  18 . Scratches are hard to be formed during CMP. 
     The fifth interlayer insulating film  18  may be made of insulating material which contains Si, O, C and H. 
     Next, with reference to FIGS. 4A to  4 G, a wiring pattern forming method according to the second embodiment will be described. A substrate formed with the layers up to the third interlayer insulating film  11  shown in FIG. 1 is prepared. A method of forming the wiring layers at levels higher than the third interlayer insulating film  11  will be described. 
     As shown in FIG. 4A, on the surface of the third interlayer insulating film  11 , a cap layer  40  of SiC having a thickness of 50 nm, a sixth interlayer insulating film  41  of low dielectric constant organic insulating material, e.g., SiLK of Dow Chemical Company having a thickness of 400 nm, a cap layer  42  of SiC having a thickness of 50 nm and a sacrificial film  43  of SiO 2  having a thickness of 100 nm are sequentially formed. The cap layers  40  and  42  and sacrificial film  43  are formed by PE-CVD. The sixth interlayer insulating film  41  is formed by coating. 
     As shown in FIG. 4B, a resist film  45  is coated on the surface of the sacrificial film  43 , and openings corresponding to a wiring pattern are formed through the resist film  45  by ordinary photolithography. By using the resist film  45  as a mask, the sacrificial film  43 , cap layer  42  and sixth interlayer insulating film  41  are etched to the intermediate depth of the sixth interlayer insulating film  41  to form wiring trenches  46 . For example, the sacrificial film  43 , cap layer  42  and sixth interlayer insulating film  41  are dry-etched by using C 4 F 6 -containing gas or CHF 3 -containing gas. After the wiring trenches  46  are formed, the resist film  45  is removed. 
     As shown in FIG. 4C, the upper surface of the sacrificial film  45  and the inner surfaces of the wiring trenches  46  are covered with a resist film  47 , and openings corresponding to via holes to be formed are formed through the resist film  47 . By using the resist film  47  as a mask, the sixth interlayer insulating film  41  is etched. For example, the sixth interlayer insulating film  41  is dry-etched by using mixed gas of NH 3  and H 2 . Via holes  48  are therefore formed and the cap layer  40  is exposed on the bottoms of the via holes. After the sixth interlayer insulating film  41  is etched, the resist film  47  is removed. 
     The cap layer  40  exposed on the bottoms of the via holes  48  is removed to expose underlying copper wiring layers. For example, the cap layer  40  is dry-etched by using CH 2 F 2 -containing gas. 
     As shown in FIG. 4D, the inner surfaces of the wiring trenches  46  and via holes  48  and the surface of the sacrificial film  43  are covered with a barrier metal layer  50   a  made of tantalum (Ta) having a thickness of 10 nm. On the surface of the barrier metal layer  50   a , a seed layer  50   b  of copper (Cu) having a thickness of 150 nm is formed. Next, copper is electroplated to form a copper layer  50   c.    
     As shown in FIG. 4E, the copper layer  50   c  is subjected to chemical mechanical polishing by using the polishing liquid with which the polishing speed of copper becomes faster than that of tantalum or silicon oxide. Since the polishing speed of tantalum and silicon oxide is relatively slow, polishing can be stopped with high reproductivity when the barrier metal layer  50   a  of tantalum or the sacrificial film  43  of SiO 2  is exposed. 
     Since the polishing speed of copper is relatively fast, dishing is formed on the surface of the copper wiring layer  50   c  left in the wiring trench  46 . It is preferable to make the sacrificial film  43  thick in order to make the deepest position of the dishing becomes higher than the bottom of the sacrificial film  43 . 
     As shown in FIG. 4F, the sacrificial film  43 , copper layer  50   c , seed layer  50   b  and barrier metal layer  50   a  are subjected to chemical mechanical polishing by using the polishing liquid with which the polishing speed of tantalum or silicon oxide becomes faster than that of copper. 
     As polishing the barrier metal layer  50   b  of tantalum and the sacrificial film  43  of SiO 2  advances, the dishing on the surface of the copper layer  50   c  shown in FIG. 4E is planarized. As polishing advances further, the exposed surface of the copper layer  50   c  protrudes. Since a polishing pressure is concentrated upon this protruded region, the surface of the copper layer  50   c  is eventually planarized. 
     As shown in FIG. 4G, when the cap layer  42  made of hydrophobic SiOC is exposed, polishing can be stopped with high reproductivity because the cap layer  42  functions as a polishing stopper layer. In the wiring trenches  46  and via holes  48 , a copper wiring layer  50  is left which is constituted of the barrier metal layer  50   a , seed layer  50   b  and copper layer  50   c . Under the polishing conditions of a relatively low polishing speed of copper, dishing is hard to be formed on the surface of the copper layer  50   c . The formation of erosion can also be prevented. 
     In the second embodiment, although the cap layer  42  is made of SiC, SiOC may also be used which is hydrophobic similar to SiC. The cap layer  42  may have a two-layer structure of an SiOC layer and an SiC layer. From the viewpoint of a dielectric constant, it is effective that the cap layer  42  is made of SiOC. However, if the SiOC layer is exposed during CMP, scratches are likely to be formed. Since the SiC layer is formed on the SiOC layer, it is possible to prevent the formation of scratches. 
     Also in the second embodiment, SiLK (trade mark of Dow Chemical Company) is used as the low dielectric constant organic material of the sixth interlayer insulating film  41 . Other materials may also be used such as polytetrafluoroethylene (PTFE), FLARE (trade mark of Honeywell Inc.), benzocyclobutene (BCB), methylsilsesquioxane (MSQ) (e.g. LKD of JSR Corporation) and the like. The material of the sixth interlayer insulating film  41  may be low dielectric constant porous insulating material instead of organic insulating material. 
     The present invention has been described in connection with the preferred embodiments. The invention is not limited only to the above embodiments. It is apparent that various modifications, improvements, combinations, and the like can be made by those skilled in the art.