Abstract:
A method of manufacturing a backside illumination image sensor includes forming an epitaxial layer on a silicon (Si) substrate, and forming an inter-metal dielectric (IMD) on the epitaxial layer. The method includes forming a trench in one side region of the epitaxial layer, forming an insulating layer at a side wall and bottom of the trench, forming a color filter and microlens on the IMD, bonding a support wafer onto the IMD with the color filter and microlens formed therein, and/or removing the Si substrate.

Description:
The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 10-2012-0060245 (filed on Jun. 5, 2012), which is hereby incorporated by reference in its entirety. 
     BACKGROUND 
     Backside illumination image sensors are devices in which a microlens and photodiode may be formed at a backside of a wafer, which may maximize illumination efficiency in some applications. In some frontside illumination image sensors, maximization of illumination efficiency may help overcome limitations in maximizing resolution and sensitivity degradation caused by metal lines. 
     Example  FIGS. 1A and 1B  illustrate sectional views of a frontside illumination image sensor and a backside illumination image sensor, respectively, in accordance with the related art. In the frontside illumination image sensor illustrated in  FIG. 1A , a microlens  100  may be formed at a frontside of a wafer. Accordingly, light  150  passing through the microlens  100  may not be efficiently transferred to a photodiode  102  due to a metal interconnection  104 , due to the photodiode  102  being disposed under the metal interconnection  104 . 
     In the backside illumination image sensor illustrated in  FIG. 1B , a microlens  100  may be formed at a backside of a wafer. Accordingly, light  150  that passes through the microlens  100  may be directly received by a photodiode  102 , which may enhance light illumination efficiency. 
     Example  FIGS. 2A to 2F  illustrate sectional views of a process of manufacturing a backside illumination image sensor using an SOI wafer, in accordance with the related art. As illustrated in  FIG. 2A , a metal interconnection  206  for an image sensor may be formed on an epitaxial layer  204  by performing a CIS process using an SOI wafer. As illustrated in  FIG. 2B , a support wafer  208  may be bonded to an upper end of a wafer in which a CMOS process has been performed for thinning the wafer, through a wafer bonding process. As illustrated in  FIG. 2C , the bonded support wafer  208  may be fixed. A grinding and chemical mechanical polishing (CMP) process may be performed on a Si substrate  200  to remove the Si substrate  200 , thereby exposing buried oxide (BOX)  202 , as illustrated in  FIG. 2D . 
     As illustrated in  FIG. 2E , the BOX  202  may be removed through wet etching. The epitaxial layer  204  in which a photodiode will be formed may remain. As illustrated in  FIG. 2F , a color filter  210 , a microlens  212 , and a support glass plate  214  may be sequentially formed over the epitaxial layer  204 , thereby completing the backside illumination image sensor. 
     In a process of manufacturing a backside illumination image sensor, Si oxide may be used or required as the etch stop layer for performing a wafer thinning process (e.g. a process that leaves a portion of silicon substantially equal to the thickness of a photodiode on a wafer and removes the other portion of silicon. An oxide layer may be required to be disposed under silicon. An SOI (silicon on insulator) wafer in which a BOX may be disposed between Si layers may be used as a substrate. However, a SOI wafer may be relatively expensive and require a complicated manufacturing process compared to the bulk Si wafer. 
     SUMMARY 
     Embodiments relate to a complementary metal-oxide semiconductor (CMOS) image sensor (CIS) and a method of manufacturing the same, which may be a backside illumination image sensor using a bulk silicon (Si) wafer without using a silicon on insulator (SOI) wafer with buried oxide (BOX). 
     In embodiments, a method of manufacturing a backside illumination image sensor may include at least one of: (1) forming an epitaxial layer on a silicon (Si) substrate; (2) forming an inter-metal dielectric (IMD) layer on the epitaxial layer; (3) forming a trench in one side region of the epitaxial layer; (4) forming an insulating layer at a side wall and bottom of the trench; (5) forming a metal interconnection on the IMD layer; (6) bonding a support wafer onto the IMD layer with the metal interconnection formed therein; and (7) removing the Si substrate. 
     In embodiments, the removing the Si substrate may include etching the Si substrate with the trench as an etch stop layer to remove the Si substrate. In embodiments, the forming of the trench may include at least one of: (1) etching the IMD layer and the epitaxial layer for the Si substrate to be exposed; (2) forming the insulating layer at the bottom and side wall of the trench; and (3) forming a conductive layer inside the trench. 
     In embodiments, the forming of the conductive layer may include at least one of: (1) forming a barrier metal at the bottom and side wall of the trench; and (2) burying the inside of the trench, in which the barrier metal is formed, with conductive materials. In embodiments, the conductive layer includes tungsten (W). In embodiments, forming the insulating layer may include at least one of: (1) forming Si oxide at the bottom and side wall of the trench; and (2) injecting nitrogen ion into the Si oxide, which is formed at the bottom and side wall of the trench, to nitrify the Si oxide. 
     In embodiments, the Si oxide may be formed with nitride by injecting the nitrogen ion into the Si oxide and performing an annealing process. In embodiments, the Si oxide may be formed to have a thickness of between approximately 1000 Å to 3000 Å. In embodiments, the trench may be a super contact trench which connects a pad and the metal interconnection. In embodiments, the trench may be formed as one or more trenches 
     In embodiments, a backside illumination image sensor may include at least one of: (1) an epitaxial layer formed on a Si substrate; (2) an inter-metal dielectric (IMD) layer formed on the epitaxial layer; (3) a super contact trench formed in one side region of the epitaxial layer; (4) an insulating layer formed at a side wall of the super contact trench; (5) a metal interconnection formed on the IMD layer; and (6) a color filter and a microlens sequentially formed over the IMD layer. 
    
    
     
       DRAWINGS 
       The above and other objects and features of embodiments will become apparent from the following description of embodiments, given in conjunction with the accompanying drawings, in which: 
       Example  FIGS. 1A and 1B  are respective sectional views of a frontside illumination image sensor and a backside illumination image sensor, in accordance with the related art. 
       Example  FIGS. 2A to 2F  are sectional views of a process of manufacturing a backside illumination image sensor, in accordance with the related art. 
       Example  FIGS. 3A to 3G  are sectional views of a process of manufacturing a backside illumination image sensor, in accordance with embodiments. 
       Example  FIGS. 4A to 4F  are sectional views of a process of manufacturing a super contact etch stop layer on the backside illumination image sensor, in accordance with embodiments. 
     
    
    
     DESCRIPTION 
     The advantages and features of embodiments and methods of accomplishing these will be clearly understood from the following description taken in conjunction with the accompanying drawings. Embodiments are not limited to those embodiments described, as embodiments may be implemented in various forms. It should be noted that embodiments are provided to make a full disclosure and also to allow those skilled in the art to know the full range of the embodiments. Therefore, the embodiments are to be defined only by the scope of the appended claims. 
     Example  FIGS. 3A to 3G  illustrate sectional views of a process of manufacturing a backside illumination image sensor using a bulk Si wafer, in accordance with embodiments. As illustrated in  FIG. 3A , an epitaxial layer  302  may be formed on a Si substrate  300 , and an IMD (inter metal dielectric) layer  304  may be formed on the epitaxial layer  302 , in accordance with embodiments. As illustrated in  FIG. 3B , a super contact etch stop layer  306  may be formed to have a thickness approximately equal to that of the epitaxial layer  302 , in accordance with embodiments. In embodiments, in the backside illumination image sensor, a Si etch stop layer such as Si nitride may be formed inside a trench for forming a super contact. The super contact etch stop layer  306  may be used as an etch stop layer to the epitaxial layer  302  in performing a wafer thinning process. 
     As illustrated in  FIG. 3C , by performing a subsequent CMOS process, a metal interconnection  308  may be finished on the epitaxial layer  302 , in accordance with embodiments. As illustrated in  FIG. 3D , a support wafer  310  may be bonded to an upper end of a wafer in which a CMOS process has been performed for thinning the wafer, through a wafer bonding process, in accordance with embodiments. As illustrated in  FIG. 3E , the bonded support wafer  310  may be fixed, and a grinding and CMP process may be performed on a Si substrate  300 , in accordance with embodiments. As illustrated in  FIG. 3F , the Si substrate  300  may then be removed from the epitaxial layer  302 , thereby exposing BOX  302 , in accordance with embodiments. 
     During the grinding and CMP process that has been performed on the Si substrate  300 , the Si substrate  300  may be etched by using a selectivity between the super contact etch stop layer  306  formed in  FIG. 3B  and a Si layer. Accordingly, as illustrated in  FIG. 3F , accurate etching of the Si layer to the epitaxial layer  302  may be enabled, in accordance with embodiments. In embodiments, the etching process on the Si substrate  300  that may be performed to the epitaxial layer  302  may etch the IMD layer that may be formed at a bottom of the super contact etch stop layer  306 . In embodiments, as illustrated in  FIG. 3G , a color filter  312 , a microlens  314 , and a support glass plate  316  are sequentially formed over the epitaxial layer  302 , thereby finishing the backside illumination image sensor. 
     Example  FIGS. 4A to 4F  illustrate sectional views of a process of manufacturing the super contact etch stop layer, in accordance with embodiments. A process of manufacturing the super contact etch stop layer, in accordance with embodiments, is described with reference to  FIGS. 4A to 4F . 
     As illustrated in  FIG. 4A , the epitaxial layer  302  on which a photodiode will be formed may be formed on the Si substrate  300 . The IMD layer  304  may then be formed on the epitaxial layer  302 . A photoresist may be coated on the IMD layer  304 . The photoresist may be patterned through a photolithography process to form a photoresist mask  400  for trench etching in a region in which a super contact will be formed. 
     As illustrated in  FIG. 4B , in the region in which the super contact will be formed, the IMD layer  304  and the epitaxial layer  302  may be sequentially etched using the photoresist mask  400  in order for the Si substrate  300  to be exposed, thereby forming a trench  402  that may be used for forming the super contact, in accordance with embodiments. 
     As illustrated in  FIG. 4C , Si oxide  404  may be formed at a surface of a wafer including the inside of the trench  402  that may be used for forming the super contact, in accordance with embodiments. In this case, the Si oxide  404  may be formed to have a thickness between approximately 1000 Å to 3000 Å by a PE-CVD process. 
     In embodiments, as illustrated in  FIG. 4D , the photoresist may be coated on the surface of the wafer. Then by patterning the photoresist through the photolithography process, a photoresist mask  406  may be formed in order for only the trench  402  of the super contact to be opened. In embodiments, a process  408  which injects nitrogen ion into the trench  402  of the super contact may be performed with the photoresist mask  406 . In embodiments, the nitrogen ion injecting process  408  may require conditions in which energy may be between approximately 10 KeV to 50 KeV and dose may be about 2 e 12  atom/cm 2  to 5 e 14  atom/cm 2    
     As illustrated in  FIG. 4E , the photoresist mask  406  may be removed. By performing an annealing process, the nitration of the Si oxide  404  may be finished, thereby forming nitride  410  inside the trench  402  of the super contact, in accordance with embodiments. In embodiments, rapid thermal process (RTP) equipment may perform the annealing process under process conditions in which a temperature may be between approximately 900° C. to 12,000° C., an atmosphere may be N 2  gas, and/or a duration may be between approximately 5 sec to 30 sec. 
     As illustrated in  FIG. 4F , a barrier metal  412  such as titanium/titanium nitride (Ti/TiN) may be formed inside the trench  402  of the super contact, for the electrical connection of the super contact, in accordance with embodiments. The inside of the trench  402  may be buried (e.g. gap-fill) with conductive materials such as tungsten (W) (in embodiments). A W plug  414  may then be formed by performing a CMP process, in accordance with embodiments. 
     In embodiments, the Si layer and the nitride having a high etch selectivity may be formed inside the super contact. In embodiments, the Si layer and the nitride may be used as the etch stop layer in performing the wafer thinning process. Accordingly, the backside illumination image sensor may be manufactured by using the bulk Si wafer without using the expensive SOI wafer, in accordance with embodiments. 
     In embodiments, a method of manufacturing a backside illumination image sensor forms an insulating layer (e.g. such as a Si layer and nitride having a high etch selectivity) inside the trench in which the super contact will be formed. Accordingly, in embodiments, when forming a super contact in a backside illumination image sensor the insulating layer may be configured to act as the etch stop layer in the etching process on the backside of the wafer for forming the photodiode. In accordance with embodiments, effective manufacturing of a backside illumination image sensor using a bulk Si wafer without using the SOI wafer with BOX may be accomplished. 
     While embodiments have been shown and described, it will be understood by those skilled in the art that various changes and modification may be made without departing the scope of the embodiments as defined the following claims.