Patent Abstract:
An interconnect structure and method for forming a multi-layered seed layer for semiconductor interconnections are disclosed. Specifically, the method and structure involves utilizing sequential catalytic chemical vapor deposition, which is followed by annealing, to form the multi-layered seed layer of an interconnect structure. The multi-layered seed layer will improve electromigration resistance, decrease void formation, and enhance reliability of ultra-large-scale integration (ULSI) chips.

Full Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a semiconductor integrated circuit interconnect structure and method of forming a multi-layered seed layer of the interconnect structure to minimize electromigration, utilizing sequential catalytic chemical vapor deposition. 
       BACKGROUND 
       [0002]    Semiconductor devices include a plurality of circuit components (i.e., transistors, resistors, diodes, capacitors, etc.) connected together to form an integrated circuit fabricated on a semiconductor substrate. A complex network of semiconductor integrated circuit interconnects (interconnects) are routed to connect the circuit components distributed on the surface of the substrate. Efficient routing of these interconnects, across semiconductor devices, requires formation of multi-level or multi-layered patterning schemes, such as single or dual damascene interconnect structures. 
         [0003]    An interconnect structure includes metal vias that run perpendicular to the semiconductor substrate. The metal vias are disposed in trench areas. In addition, an interconnect structure includes metal lines that are disposed in the trench areas, wherein the trench areas are formed in dielectric material. The metal vias are connected to the metal lines, and the metal lines run parallel to the semiconductor substrate. Thus, both the metal lines and metal vias are disposed proximately to the dielectric material having a dielectric constant of less than 5.0, which enhances signal speed and minimizes signal crosstalk (i.e., crosstalk refers to a signal being transmitted through a metal line, and affecting another signal being transmitted through a separate metal line, and/or affecting other parts of circuitry in an undesired manner). 
         [0004]    Furthermore, interconnect structures that are copper (Cu) based, when compared with aluminum (Al) based interconnect structures, provide higher speed signal transmission between large numbers of transistors on a complex semiconductor chip. Accordingly, when manufacturing integrated circuits, copper (i.e., a metal conductor) is typically used for forming the semiconductor integrated circuit&#39;s interconnects because of copper&#39;s low resistivity and high current carrying capacity. Resistivity is the measure of how much a material opposes electric current, due to a voltage being placed across the material. However, when copper is utilized to form interconnects electromigration may occur. Electromigration can result in void formation, as well as extrusion/hillock formation. Integrated circuit manufacturers generally have electromigration requirements that should be satisfied as part of an overall quality assurance validation process, but thereafter electromigration may still persist during the lifetime of an integrated circuit in a user&#39;s computer (i.e., when current flows through the semiconductor integrated circuit&#39;s interconnect structure). 
         [0005]    Specifically, electromigration is the gradual displacement of atoms of a metal conductor, due to high density of current passing through the metal conductor, and electromigration is accelerated when the temperature of the metal conductor increases. Since a semiconductor integrated circuit&#39;s interconnect structure is generally formed using copper, which is a metal conductor susceptible to electromigration, electromigration presents a problem when utilizing integrated circuits with copper based interconnects. 
         [0006]    Electromigration (i.e., the gradual displacement of metal atoms from one location to another location throughout a metal conductor, due to the high density of current flow) can result in void formation, as well as extrusion/hillock formation in a semiconductor integrated circuit&#39;s interconnect structure. The voids can result in an open circuit if one or more voids formed are large enough to sever the interconnect structure, and the extrusions/hillocks can result in a short circuit if one or more extrusions/hillocks are sufficiently long to form a region of abnormally low electrical impedance. Accordingly, void formation and extrusion/hillock formation, due to electromigration, can reduce integrated circuit performance, decrease reliability of interconnects, cause sudden data loss, and reduce the useful life of semiconductor integrated circuit products. 
       SUMMARY 
       [0007]    The present invention relates to a semiconductor integrated circuit interconnect structure (interconnect structure) and method of forming the interconnect structure to minimize electromigration. Minimizing electromigration can improve integrated circuit performance, enhance reliability of interconnect structures, minimize sudden data loss, and enhance the useful lifetime of semiconductor integrated circuit products. 
         [0008]    A first aspect of the present invention provides an interconnect structure comprising: one or more openings in a dielectric layer; a barrier metal layer disposed on the dielectric layer; a multi-layered seed layer disposed on the barrier metal layer, wherein the multi-layered seed layer comprises at least three layers; an electroplated copper layer disposed on the multi-layered seed layer; a planarized surface, wherein a portion of the barrier metal layer, the multi-layered seed layer, and the electroplated copper layer are removed; and a capping layer disposed on the planarized surface. 
         [0009]    A second aspect of the present invention provides a method of performing a sequential catalytic chemical vapor deposition (CVD) process by utilizing a catalytic CVD apparatus, the method comprising the steps of: forming one or more openings in a dielectric layer; forming a barrier metal layer disposed on the dielectric layer; forming a multi-layered seed layer disposed on the barrier metal layer, wherein the multi-layered seed layer comprises at least three layers; forming an electroplated copper layer disposed on the multi-layered seed layer; forming a planarized surface, wherein a portion of the barrier metal layer, the multi-layered seed layer, and the electroplated copper layer are removed; and forming a capping layer disposed on the planarized surface. 
         [0010]    A third aspect of the present invention provides a catalytic chemical vapor deposition apparatus comprising: a catalytic chemical vapor deposition (CVD) processing chamber, wherein the catalytic CVD processing chamber comprises a heatable metal wire, a heatable plate; and a heatable tank operatively coupled to the catalytic CVD processing chamber. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0011]    The subject matter which is regarded as an embodiment of the present invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. One manner in which recited features of an embodiment of the present invention can be understood is by reference to the following detailed description of embodiments, taken in conjunction with the accompanying drawings in which: 
           [0012]      FIG. 1  is a pictorial representation (i.e., cross-sectional view) of a semiconductor illustrating the formation of trench areas and via holes (i.e., vias) according to one embodiment of the present invention. 
           [0013]      FIG. 2  depicts a top view of an array of trench areas and via holes (i.e., vias) according to one embodiment of the present invention. 
           [0014]      FIGS. 3A-3D  are pictorial representations (i.e., cross-sectional views) illustrating the formation of trench areas and via holes with a barrier metal layer, a multi-layered seed layer, an electroplated copper layer, and a dielectric capping layer according to one embodiment of the present invention. 
           [0015]      FIG. 4  depicts a cross-sectional view of a catalytic chemical vapor deposition (CVD) processing chamber and heatable tank adapted to deliver metal ions and precursor gases to a substrate according to one embodiment of the present invention. 
           [0016]      FIG. 5  is a method flow block diagram illustrating a method for forming a multi-layered seed layer of a semiconductor integrated circuit interconnect structure according to one embodiment of the present invention. 
       
    
    
       [0017]    The drawings are not necessarily to scale. The drawings, some of which are merely pictorial and schematic representations, are not intended to portray specific parameters of the invention. The drawings are intended to depict only typical embodiments of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements. 
       DETAILED DESCRIPTION 
       [0018]    Exemplary embodiments now will be described more fully herein with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of this disclosure to those skilled in the art. In the description, details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the presented embodiments. 
         [0019]    The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, the use of the terms “a”, “an”, etc., do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. It will be further understood that the terms “comprises” and/or “comprising”, or “includes” and/or “including”, when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof. 
         [0020]    In addition it will be understood that when an element as a layer, region, or substrate is referred to as being “on” or “over”, or “disposed on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on”, “directly over”, or “disposed proximately to” another element, there are no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or directly coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. 
         [0021]    Embodiments of the present invention provides a semiconductor integrated circuit interconnect structure (interconnect structure) that minimizes electromigration, which thereby can minimize void formation and extrusion/hillock formation. Minimizing electromigration can improve integrated circuit performance, enhance reliability of interconnect structures, minimize sudden data loss, and enhance the useful lifetime of semiconductor integrated circuit products. 
         [0022]      FIG. 1  illustrates a cross-sectional view of semiconductor  100  comprising a substrate  102 , transistor area layer  104 , first dielectric layer  106 , first metal layer  108 , second dielectric layer  110 , and openings in the second dielectric layer  110  for trench areas  112 - 114  and via hole  116 . Specifically, dielectric layer  106  is formed on transistor area layer  104 , wherein transistor area layer  104  is formed on substrate  102 . Subsequent to a chemical-mechanical planarization (CMP) process of the first dielectric layer  106  with first metal layer  108 , a second dielectric layer  110  is formed over first metal layer  108  and first dielectric layer  106 . Moreover, trench areas  112 - 114  and a via hole  116  are formed in second dielectric layer  110 . Specifically, via hole  116  is formed in trench area  113 . Consequently, a dual damascene structure, which includes trench areas  112 - 114  and a via hole  116 , is formed. 
         [0023]      FIG. 2  is a top view of an array of trench areas and via holes. Specifically,  FIG. 2  depicts an array of trench areas  215 - 218  and via holes  206 - 211 . A trench may not have any via holes such as trench area  215 . However, trench areas can have one or more via holes such as depicted in trench areas  216 - 218 . Moreover, via holes can be distributed uniformly in a trench area as illustrated in trench area  216 , wherein in via hole  206  is formed symmetrically opposite to via hole  207 , in trench area  216 . Alternatively, via holes can be distributed non-uniformly in a trench area as illustrated in trench areas  217 - 218 . Lastly, there are one or more via holes at each level of semiconductor interconnects in order for all levels of the semiconductor interconnects to be electrically connected. 
         [0024]      FIG. 3A  depicts a cross-sectional view of substrate  102 , transistor area layer  104 , first dielectric layer  106 , first metal layer  108 , second dielectric layer  110 , trench areas  112 - 114 , via hole  116  (shown in  FIG. 1 ), barrier metal layer  302 , first copper seed layer  306 , second seed layer  307 , and second copper seed layer  308 . 
         [0025]    Specifically, the barrier metal layer  302  is disposed on trench areas  112 - 114 . The barrier metal layer  302  prevents conducting material, such as copper, from diffusing into the dielectric layer  110 . A multi-layered seed layer is formed directly on barrier metal layer  302 . The multi-layered seed layer comprises a first copper seed layer  306 , a second seed layer  307 , and a second copper seed layer  308 . The first copper seed layer  308  is formed utilizing a sequential catalytic chemical vapor deposition (CVD) process. Utilizing the sequential catalytic CVD process allows for trench areas and via holes to be filed, and minimizes pinch-offs, void formation, and extrusion/hillock formation. Specifically, to form first copper seed layer  306 , copper(II) chloride and hydrogen gases are utilized in the sequential catalytic CVD process, wherein first copper seed layer  306  is disposed on barrier metal layer  302 . 
         [0026]    Next, second seed layer  307  is disposed on first copper seed layer  306  utilizing the sequential catalytic CVD process. Specifically, to form the second seed layer  307 , hydrogen gas, ammonia gas, and carrier gas argon are utilized with manganese amidinate precursor. In the present embodiment manganese is utilized to form second seed layer  307 , but in alternative embodiments aluminum, tin, or titanium may be utilized to form second seed layer  307 . After the second seed layer  307  is formed, second copper seed layer  308  is formed utilizing the sequential catalytic CVD process, wherein the second copper seed layer  308  is disposed on second seed layer  307 . Accordingly, the multi-layered seed layer is formed. 
         [0027]      FIG. 3B  illustrates the formation of an electroplated copper layer  309 . Specifically, the electroplated copper layer  309  is disposed on the second copper seed layer  308 . As a result, unfilled trench areas  112 - 114  (shown in  FIG. 3A ) and via hole  116  (shown in  FIG. 1 ) are filled with copper, utilizing an electroplating technique. In addition, post plating anneal  320  occurs causing copper grain growth. However, the post plating anneal  320  does not result in much diffusion of the multi-layered seed layer. 
         [0028]      FIG. 3C  illustrates an end result of a chemical-mechanical planarization (CMP) process. The purpose of the CMP process is to remove a portion of layers  302  and  306 - 308 , which provides for the formation of a quality interconnect structure, and clears the way for forming a dielectric layer capping layer and/or a selective metal capping layer. 
         [0029]      FIG. 3D  illustrates the formation of a dielectric capping layer. In the present embodiment, dielectric capping layer  312  is formed after the CMP process illustrated in  FIG. 3C . The dielectric capping process occurs at temperatures high enough (i.e., between about 350° C.-400° C.) to enhance copper grain growth of first copper seed layer  306  (shown in  FIG. 3C ) and second copper seed layer  308  (shown in  FIG. 3C ), and enhance diffusion of second seed layer  307  (shown in  FIG. 3C ) with seed layer  306 , seed layer  308 , and with electroplated copper layer  309  (shown in  FIG. 3C ). As a result, second seed layer  307  diffuses with first copper seed layer  306 , diffuses with second copper seed layer  308 , and diffuses with electroplated copper layer  309 , which causes layers  306 - 309  to merge, forming a single second metal layer  314  comprising a copper-manganese alloy. Furthermore, as a result of the diffusion process, triggered by the formation of dielectric capping layer  312 , a high concentration of manganese remains at the interface between dielectric capping layer  312  and second metal layer  314 . Accordingly, the high concentration of manganese forms a segregated manganese-containing layer  316  at the interfaces between dielectric capping layer  312  and second metal layer  314 . Additionally, a via hole opening can be created in dielectric capping layer  312  to provided connectivity to a subsequent metal layer. In alternative embodiments, a selective metal capping layer may be deposited over segregated manganese-containing layer  316 , wherein subsequently a dielectric capping layer  312  may be deposited over the selective metal capping layer, and wherein the capping process occurs at temperatures between about 350° C.-400° C. 
         [0030]      FIG. 4  depicts a schematic cross-sectional view of a chemical deposition apparatus  400  comprising a catalytic chemical vapor deposition (CVD) processing chamber  418  and heatable tank  434 , adapted to deliver metal ions and precursor gases to a substrate, and adapted to form a multi-layered seed layer. Gas line  404  is utilized to deliver copper(II) chloride gas  402  into gas line  414 . The gas line  404  is connected to a mass flow controller  406 , and a gas line  414 . The copper(II) chloride gas  402  passes through gas line  404 , mass flow controller  406 , and then into the gas line  414 . The purpose of a mass flow controller is to control the rate of gas flow through a gas line. Gas line  410  is utilized to deliver hydrogen gas  408  into gas line  414 . The gas line  410  is connected to a mass flow controller  412 , and the gas line  414 . The hydrogen gas  408  passes through gas line  410 , mass flow controller  412 , and then into the gas line  414 . In one embodiment, a gas line  410  is utilized to deliver hydrogen gas  408  into gas line  414 , wherein gas line  404  is simultaneously utilized to deliver the copper(II) chloride gas  402  into gas line  414 . 
         [0031]    Accordingly, gas lines  404  and  410  merge into one gas line  414 , wherein gas line  414  is connected to inlet  416  of catalytic CVD processing chamber  418 . Gas line  414  contains both copper(II) chloride gas  402  and hydrogen gas  408 , which are introduced into the inlet  416  of catalytic CVD processing chamber  418 . In one embodiment catalytic CVD processing chamber  418  comprises an inlet  416 , a heated metal wire  420 , a side inlet  454 , a heatable plate  426 , a wafer  424 , and a gas discharge outlet  458  for gases to exit by turbo molecular pumping  460 . In addition, a barrier metal layer  302  (shown in  FIG. 3A ) is disposed on the surface of wafer  424 , wherein in the barrier metal layer  302  is deposited utilizing physical vapor deposition prior to entering catalytic CVD processing chamber  418 . However, the barrier metal layer  302  can be deposited in a separate chamber by utilizing other processes, which include atomic layer deposition (ALD). 
         [0032]    After the copper(II) chloride gas  402  and hydrogen gas  408  pass through gas line  414  and are introduced into inlet  416 , the copper(II) chloride gas  402  and hydrogen gas  408  are then heated by metal wire  420 . Metal wire  420  comprises tungsten, but can be made of other useful materials which include ruthenium, rhodium, palladium, osmium, iridium, platinum, gold, silver, mercury, rhenium, copper or a combination thereof. At the surface of heated metal wire  420  the copper(II) chloride gas  402  reacts with the hydrogen gas  408 , and the copper(II) chloride gas  402  decomposes into copper radicals  422 . The copper radicals  422  are then deposited directly on to the surface of the barrier metal layer  302 , to form first copper seed layer  306  (shown in  FIG. 3A ). Although the wafer  424  is directly on heatable plate  426 , the plate is not very hot. Typically, CVD needs to occur at a high temperature, however in the present embodiment copper decomposition happens as a result of the heated metal wire  420 , which forms copper radicals  422 . Therefore, heatable plate  426  does not have to be heated to as a high temperature as other CVD processes may require. Specifically, the temperature of the heatable plate  426  may be between about 20° C.-150° C. 
         [0033]    After first copper seed layer  306  is deposited on wafer  424 , the catalytic CVD processing chamber  418  is cleaned. Next, gas line  428  is utilized to deliver a carrier gas  426  into heatable tank  434 . In the present embodiment, the carrier gas argon  426  is utilized, but other gases may be used including nitrogen gas (N 2 ). Subsequently, gas line  428  delivers carrier gas argon  426  through a mass flow controller  430 , and through inlet  432  of heatable tank  434 , wherein the heatable tank  434  holds a manganese amidinate precursor  436 . Thus, the carrier gas  426  is delivered into the manganese amidinate precursor  436 . The manganese amidinate precursor  436  becomes liquid vaporized, which forms a vapor  438 . The vapor  438  is discharged through outlet  440  of heatable tank  434 , and introduced into gas line  444 . The vapor  438  includes manganese amidinate precursor  436 . Pressure gauge  442  is connected to gas line  444 , and can be utilized to determine how much manganese amidinate precursor is in vapor  438 . In the present embodiment, the manganese amidinate precursor  436  is utilized, but in alternative embodiments other liquid solutions may be utilized, which include carbonyl precursors. 
         [0034]    Next, ammonia (NH 3 ) and hydrogen (H 2 ) gases  446  are introduced into gas line  448 . The ammonia and hydrogen gases  446  pass through a mass flow controller  450 . Gas line  448  merges with gas line  444  forming gas line  452 , wherein gas line  452  is connected to side inlet  454  of catalytic CVD processing chamber  418 . As a result, the vapor  438  flowing through gas line  444  merges with the ammonia and hydrogen gases  446  flowing through gas line  448 , wherein the combined vapor  438  and ammonia and hydrogen gases  446  then flow through gas line  452 . Gas line  452  delivers the combined vapor  438  and ammonia and hydrogen gases  446  into catalytic CVD processing chamber  418 , through side inlet  454  forming a stream of gas flow  456 . At the top surface of first copper seed layer  306  the combined vapor  438  and ammonia and hydrogen gases  446  cause the manganese amidinate precursor  436  in vapor  438  to decompose, wherein the manganese atoms of the manganese amidinate precursor  436  are separated from the nitrogen atoms of the manganese amidinate precursor  436 . Thus, the manganese atoms are deposited directly on the top surface of first copper seed layer  306 , forming a second seed layer  307 . The ammonia and hydrogen gases  446  and nitrogen atoms, wherein the nitrogen atoms were once bonded to the manganese, are evacuated from processing chamber  418  through the gas discharge outlet  458  by utilizing a turbo molecular pumping  460 . Accordingly, a second seed layer  307  (shown in  FIG. 3C ) is disposed on the top surface of first copper seed layer  306 . In the present embodiment manganese is utilized to form precursor  436  and second seed layer  307 , but in alternative embodiments aluminum, tin, or titanium may be utilized to form precursor  436  and second seed layer  307 . 
         [0035]    After second seed layer  307  is disposed on the top surface of first copper seed layer  306 , the catalytic CVD processing chamber  418  is cleaned. Next, copper(II) chloride gas  402  is introduced into gas line  404 , and hydrogen gas  408  is introduced into gas line  410 . The copper(II) chloride gas  402  passes through mass flow controller  406  and the hydrogen gas  408  passes through mass flow controller  412 . 
         [0036]    Next, gas lines  404  and  410  merge into one gas line  414 , wherein gas line  414  is connected to inlet  416  of catalytic CVD processing chamber  418 . Thus, gas line  414  contains both copper(II) chloride gas  402  and hydrogen gas  408 , which are introduced into the inlet  416  of catalytic CVD processing chamber  418 . In one embodiment catalytic CVD processing chamber  418  comprises an inlet  416 , a heated metal wire  420 , a side inlet  454 , a heatable plate  426 , a wafer  424 , and a gas discharge outlet  458  for gases to exit by turbo molecular pumping  460 . 
         [0037]    After the copper(II) chloride gas  402  and hydrogen gas  408  pass through gas line  414  and are introduced into inlet  416 , the copper(II) chloride gas  402  and hydrogen gas  408  are then heated by metal wire  420 . The metal wire  420  may be heated between about 1000° C.-1500° C. Metal wire  420  comprises tungsten. At the surface of heated metal wire  420  the copper(II) chloride gas  402  reacts with the hydrogen gas  408 , and the copper(II) chloride gas decomposes into copper radicals  422 . The copper radicals  422  are then deposited directly on the surface of the second seed layer  307 , to form second copper seed layer  308  (shown in  FIG. 3A ). Although the wafer  424  is directly on heatable plate  426 , the plate is not very hot. Typically, CVD needs to occur at a high temperature, however in the present embodiment copper decomposition happens as a result of the heated metal wire  420 , which forms copper radicals  422 . Therefore, heatable plate  426  does not have to be heated to as a high temperature as other CVD processes may require. After forming of the second copper seed layer  308 , the formation of the multi-layered seed layer is completed. Next an electroplated copper layer is formed in a separate chamber. Subsequently, in the present embodiment, processes such as chemical-mechanical planarization and the formation of dielectric capping layer  312  (shown in  FIG. 3D ) may be initiated. In alternative embodiments, a selective metal capping layer may be deposited over segregated manganese-containing layer  316 , wherein subsequently a dielectric capping layer  312  may be deposited over the selective metal capping layer, and wherein the capping process occurs at temperatures between about 350° C.-400° C. 
         [0038]    Referring now to  FIG. 5 , a method for forming a semiconductor integrated circuit interconnect structure with a multi-layered seed layer is depicted. In step  500 , source gases which include copper(II) chloride gas  402  (shown in  FIG. 4 ) and hydrogen gas  408  (shown in  FIG. 4 ) are provided. In step  502 , the source gases are released into a catalytic chemical vapor deposition chamber  418  (shown in  FIG. 4 ), wherein the catalytic CVD processing chamber  418  includes a wafer directly on a heatable plate  426  (shown in  FIG. 4 ). In step  504 , a metal wire  420  (shown in  FIG. 4 ) is heated. Next, in step  506  the metal wire  420  that is sufficiently heated causes the copper(II) chloride gas  402  to react with the hydrogen gas  408 , at the surface of metal wire  420 , such that the copper(II) chloride gas  402  decomposes into copper radicals  422  (shown in  FIG. 4 ). In step  507 , a determination is made as to whether a second seed layer  307  (shown in  FIG. 3A ) has been formed. Since a second seed layer  307  has not been formed the process will proceed to step  508 . In step  508 , the copper radicals  422  are deposited directly on a barrier metal layer  302  (shown in  FIG. 3A ), wherein in the barrier metal layer  302  is disposed on the surface of the wafer  424  (shown in  FIG. 4 ), and wherein a first copper seed layer  306  (shown in  FIG. 3A ) is formed. In step  510 , a determination is made as to whether a second copper seed layer has been formed. Since a second copper seed layer  308  (shown in  FIG. 3A ) has not been formed the process will proceed to step  512 , wherein the catalytic CVD processing chamber  418  is cleaned in preparation for the next step in the formation of the multi-layered seed layer. 
         [0039]    In step  514 , a carrier gas argon  426  (shown in  FIG. 4 ), and ammonia and hydrogen gases  446  (shown in  FIG. 4 ) are provided. In step  516 , the carrier gas argon  426  is released into a heatable tank  434  (shown in  FIG. 4 ), wherein the heatable tank  434  contains manganese amidinate precursor  436  (shown in  FIG. 4 ). In step  518 , a vapor  438  (shown in  FIG. 4 ) is formed inside of heatable tank  434 , and the vapor  438  includes the manganese amidinate precursor  436 . In step  520 , the vapor  438  is discharged out of heatable tank  434  and combines with the ammonia and hydrogen gases  446 . In step  522 , the combined vapor  438 , and ammonia and hydrogen gases  446  are released into the catalytic chemical vapor deposition chamber  418 . In step  524 , the manganese amidinate precursor  436  is decomposed at the top surface of copper seed layer  306 . Specifically, in step  524 , at the top surface of copper seed layer  306  the combined vapor  438  and ammonia and hydrogen gases  446  cause the manganese amidinate precursor  436  to decompose, wherein the manganese atoms of the manganese amidinate precursor  436  are separated from the nitrogen atoms of the manganese amidinate precursor  436 . Thus, the manganese atoms are deposited directly on the top surface of first copper seed layer  306 , forming a second seed layer  307 . Next, in step  526 , nitrogen, and ammonia and hydrogen gases  446  are evacuated from the catalytic CVD processing chamber  418  by utilizing turbo molecular pumping  460 . In step  528 , the catalytic CVD processing chamber  418  is cleaned. In the present embodiment manganese is utilized to form the precursor  436  and the second seed layer  307 , but in alternative embodiments aluminum, tin, or titanium may be utilized to form the precursor  436  and the second seed layer  307 . 
         [0040]    In step  528 , after the catalytic CVD processing chamber  418  is cleaned, the method of forming a semiconductor integrated circuit interconnect structure with a multi-layered seed layer proceeds back to step  500 . In step  500 , source gases which include copper(II) chloride gas  402  and hydrogen gas  408  are provided. In step  502 , the source gases are released into a catalytic chemical vapor deposition chamber  418 , wherein the catalytic CVD processing chamber  418  includes a wafer directly on a heatable plate  426 . In step  504 , a metal wire  420  is heated. Next, in step  506  the metal wire  420  that is sufficiently heated causes the copper(II) chloride gas  402  to react with the hydrogen gas  408 , at the surface of metal wire  420 , such that the copper(II) chloride gas  402  decomposes into copper radicals  422 . In step  507 , a determination is made as to whether a second seed layer  307  has been formed. Since a second seed layer  307  has been formed the process will proceed to step  509 . In step  509 , the copper radicals  422  are deposited directly on the second seed layer  307 , wherein a second copper seed layer  308  (shown in  FIG. 3A ) is formed. In step  510 , a determination is made as to whether a second copper seed layer has been formed. Since the second copper seed layer  308  has been formed the process will end at step  530 , wherein the formation of the multi-layered seed layer is completed. 
         [0041]    The method flow diagram depicted in  FIG. 5  illustrates a method for forming a multi-layered seed layer of a semiconductor integrated circuit interconnect structure, according to various embodiments of the present invention. It should also be noted that, in some alternative implementations, the process steps noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be performed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the process involved. It will also be noted that each block of the block diagram and/or flowchart illustration, and combinations of blocks in the block diagram and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified processes or acts, or combinations of special purpose hardware and computer instructions. 
         [0042]    Furthermore, those skilled in the art will note from the above description, that presented herein is a novel apparatus and method for forming a multi-layered seed layer to minimize electromigration, utilizing sequential catalytic chemical vapor deposition. Lastly, the foregoing description of various aspects of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed and, obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of the invention as defined by the accompanying claims.

Technology Classification (CPC): 7