Patent Abstract:
A method of protecting a shallow trench isolation structure is described, which is applied to a semiconductor device process that includes a first process causing a recess in the STI structure and a second process after the first process. The method includes forming a silicon nitride layer in the recess along the profile of the same during the second process.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to a semiconductor process, and more particularly relates to a method of protecting a shallow trench isolation (STI) structure from damages in etching and/or cleaning and to a composite structure resulting from the same method. 
         [0003]    2. Description of Related Art 
         [0004]    The major isolation structure applied to highly integrated semiconductor devices currently is the shallow trench isolation (STI) structure, which is generally fabricated by forming a trench in a semiconductor substrate and filling the trench with an insulating material. The STI structure is readily scalable and does not suffer from a bird&#39;s beak issue present in a local oxidation (LOCOS) process for forming field oxide isolation, thus being a more ideal type of isolation structure for sub-micron MOS processes. 
         [0005]      FIG. 1  depicts a top view of a layout of a semiconductor device structure in the prior art, and  FIG. 2  depicts a cross-sectional view of the same along the line A-A′. Referring to  FIGS. 1 and 2 , a STI structure  102  is formed in the substrate  100  to define active areas  103 , conductive lines  104  are formed over the substrate  100  crossing over the STI structure  102  and the active areas  103 , and spacers  106  are disposed on the sidewalls of the conductive lines  104 . 
         [0006]    In a MOS process, multiple etching and cleaning steps are conducted, such as the etching step for removing a cap layer and a hard mask layer, the pre-cleaning step done before a salicide layer is formed, the cleaning step conducted after the spacers  106  are formed, and the cleaning step conducted after the source/drain regions are formed, etc. 
         [0007]    During the etching and cleaning, the upper portion of each STI structure  102  is damaged to form a recess  108 , which possibly has a depth of 800 angstroms or more. Certain wet-etching steps and cleaning steps, especially the pre-cleaning step before the salicide process, cause lateral corrosion to the STI structures  102  so that the recesses  108  extend to below the spacers  106  or even below the conductive lines  104 . 
         [0008]    In a later deposition step for an inter-layer dielectric (ILD) layer (not shown), seams are formed in the ILD layer due to the presence of the recesses  108 . Meanwhile, the deposited material is difficult to fill in the parts of the recesses  108  under the spacers  106  so that there are still hollow spaces under the spacers  106  after the ILD deposition. 
         [0009]    It is found that the seams in the ILD layer and the recesses  108  under the spacers  106  lower the isolation effect of the STI structure to cause current leakage. Moreover, in the step of forming tungsten contacts in the ILD layer, tungsten easily fills into the ILD seams and the hollow spaces under the spacers  106  due to its superior gap-filing capability, so that two neighboring tungsten contacts are easily shorted. 
       SUMMARY OF THE INVENTION 
       [0010]    Accordingly, this invention provides a method of protecting a shallow trench isolation structure, which at least prevents two neighboring contacts from being shorted. 
         [0011]    This invention also provides a composite structure resulting from the method of protecting a shallow trench isolation structure of this invention. 
         [0012]    A method of protecting a shallow trench isolation structure of this invention is applied to a semiconductor device process that includes a first process causing a recess in the STI structure and a second process after the first process. The method includes formation of a silicon nitride layer in the recess along the profile of the same during the second process. 
         [0013]    In an embodiment, the etching rate of the silicon nitride layer is lower than that of the STI structure. The STI structure may include silicon oxide. 
         [0014]    In an embodiment, the first process includes an etching process or a cleaning process. 
         [0015]    In an embodiment, the second process includes forming a salicide block layer for semiconductor devices isolated by the STI structure, and the salicide block layer and the silicon nitride layer are formed from the same silicon nitride base layer. In another embodiment, the second process includes forming spacers of semiconductor devices isolated by the STI structure, and the spacers and the silicon nitride layer are formed from the same silicon nitride base layer. In still another embodiment, the second process includes forming spacers of semiconductor devices isolated by the STI structure and forming a salicide block layer for semiconductor devices isolated by the STI structure, and the silicon nitride layer includes a first sub-layer and a second sub-layer, wherein the first sub-layer and the salicide block layer are formed from a first silicon nitride base layer, and the second sub-layer and the spacers are formed from a second silicon nitride base layer. 
         [0016]    Another method of protecting an STI structure of this invention is applied to a semiconductor device process that includes forming a salicide block layer for semiconductor devices isolated by the STI structure and forming a salicide layer later. In the method, a protection layer is formed over the substrate covering the STI structure after the STI structure is formed but before the salicide block layer is formed, and then the portions of the protection layer not over the STI structure are removed. The etching rate of the protection layer may be lower than that of the STI structure. The protection layer may include silicon nitride, silicon-rich silicon oxide or silicon oxynitride. 
         [0017]    The composite structure of this invention includes an STI structure in the substrate and a protection layer and is formed during a semiconductor device process, wherein the STI structure has a recess thereon and the protection layer covers the recess. 
         [0018]    The protection layer may have a lower etching rate than the STI structure The STI structure may include silicon oxide. The protection layer may include silicon nitride, silicon-rich silicon oxide or silicon oxynitride. 
         [0019]    In an embodiment, the protection layer and a salicide block layer formed for semiconductor devices isolated by the STI structure are formed from the same base layer in the semiconductor device process. In another embodiment, the protection layer and spacers of semiconductor devices isolated by the STI structure are formed from the same base layer in the semiconductor device process. In still another embodiment, the protection layer includes a first sub-layer and a second sub-layer, wherein the first sub-layer and a salicide block layer formed for semiconductor devices isolated by the STI structure are formed from a first base layer, and the second sub-layer and spacers of semiconductor devices isolated by the STI structure are formed from a second base layer. 
         [0020]    In an embodiment, the surface of the recess is lower than that of the substrate so that at least a portion of the protection layer is located in a trench in which the STI structure is disposed. 
         [0021]    Because a protection layer is disposed on the STI structure having a recess thereon, it is possible to prevent deepening and lateral extension of the recess in subsequent etching and cleaning, so that the isolation effect of the STI structure is maintained. Further, because the protection layer prevents extension of recesses on the isolation layer and thereby inhibits formation of seams in the ILD, two neighboring contacts are prevented from being shorted with this invention. 
         [0022]    It is also noted that by integrating the forming steps of the protection layer with those of one or more other functional layers like salicide block layer and/or spacer, the semiconductor device process does not become more complicated. 
         [0023]    In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, a preferred embodiment accompanied with figures is described in detail below. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]      FIG. 1  depicts a top view of the layout of a semiconductor device structure in the prior art. 
           [0025]      FIG. 2  depicts a cross-sectional view of the structure of  FIG. 1  along line A-A′. 
           [0026]      FIG. 3  depicts a top view of the layout of a semiconductor device structure at the start of a process flow for forming a protection layer on the STI structure according to a first embodiment of this invention. 
           [0027]      FIGS. 4A-4C  depict, in a cross-sectional view along the line B-B′ in  FIG. 3 , the process flow according to the first embodiment of this invention. 
           [0028]      FIG. 5  depicts a top view of a composite structure including an STI structure and a protection layer thereon according to a second embodiment of this invention. 
           [0029]      FIG. 6  depicts a cross-sectional view of the composite structure of  FIG. 5  along the line C-C′. 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0030]    It is particularly noted that the above protection layer on the STI structure may be formed from an additional material layer that was never formed in the corresponding semiconductor device process of the prior-art, or alternatively be formed from one or more material layers used to form other functional layers in a semiconductor device process. In the latter way, the forming steps of the protection layer are integrated with those of one or more other functional layers in the semiconductor device process. 
       First Embodiment 
       [0031]      FIG. 3  depicts a top view of the layout of a semiconductor device structure at the start of a process flow for forming a protection layer on the STI structure according to the first embodiment of this invention.  FIGS. 4A-4C  depict, in a cross-sectional view along the line B-B′ in  FIG. 3 , the above process flow. In this embodiment, the forming steps of the protection layer are integrated with those of one or more other functional layers in a semiconductor device process. 
         [0032]    Referring to  FIGS. 3 &amp; 4A , a substrate  200  is provided, with an STI structure  202  formed therein to define active areas  203  and conductive lines  204  formed thereon that cross over the isolation structures  202  and possibly include doped polysilicon. The STI structure  202  may include silicon oxide. The STI structure  202  and the conductive lines  204  can be formed with any suitable process in the prior art. 
         [0033]    It is noted that after the STI structure  202  is formed, the etching step for defining the conductive lines  204  and a later cleaning step easily corrode the STI structure  202  to form therein recesses  205  each having a surface lower than that of the substrate  200 , which however do not affect the isolation effect of the STI structure  202  or make neighboring contacts formed later be shorted. 
         [0034]    Referring to  FIG. 4B , spacers  206  of the semiconductor devices isolated by the STI structure  202  are formed on the sidewalls of the conductive lines  204  that are also a part of the semiconductor devices, and simultaneously a protection layer  208  is formed in each recess  205  along the profile of the same. Since the surface of each recess  205  is lower than that of the substrate  200 , at least a portion of the protection layer  208  is disposed in the trench in which the STI structure  202  is disposed. The spacers  206  and the protection layer  208  are formed from the same base layer, and the protection layer  208  has a lower etching rate than the STI structure  202 . To form the spacers  206  and the protection layer  208 , it is possible to deposit a silicon nitride base layer over the substrate  200  through CVD and then etch back the same such that the portions thereof on the sidewalls of the conductive lines  204  and on the STI structure  202  are retained. 
         [0035]    Referring to  FIG. 4C , a protection layer  210  is formed on the STI structure  202 , and simultaneously a salicide block layer (not shown) is formed over the substrate  200  for some semiconductor devices isolated by the STI structure  202 . The salicide block layer and the protection layer  210  are formed from the same base layer, and the protection layer  210  has a lower etching rate than the STI structure  202 . To form the salicide block layer and the protection layer  210 , it is possible to deposit a silicon nitride base layer over the substrate  200  through CVD and then pattern the same such that the regions of the substrate  200  on which a salicide layer is to be formed are exposed, while the portions of the silicon nitride base layer on the STI structure  202  and on the regions of the substrate  200  not requiring salicide are retained. 
         [0036]    It is particularly noted that when the two protection layers  208  and  210  together are considered as one protection layer, each of the two protection layers  208  and  210  is considered as a sub-layer of the one protection layer. 
         [0037]    It is noted that though two protection layers  208  and  210  are successively formed over the STI structure  202  in the first embodiment, this invention is not limited to form two protection sub-layers but may alternatively form only one protection layer simultaneously with a functional layer like a salicide block layer or a spacer. 
         [0038]    It is also noted that when only one protection layer is formed simultaneously with a salicide block layer in a later stage of a MOS process, the accumulative corrosion to the STI structure during previous steps makes a deeper recess thereon. In such a case, however, the protection layer still effectively ensures the isolation effect of the STI structure as being formed still before the pre-cleaning step prior to the salicide process which would damage an unprotected STI structure badly. 
         [0039]    Accordingly, since a protection layer (possibly including two sub-layers  208  and  210 ) is formed on the STI structure  202 , it is possible to prevent deepening or lateral extension of the recesses on the same in subsequent etching and cleaning. Hence, the isolation effect of the STI structure can be maintained and neighboring contacts can be prevented from being shorted. 
         [0040]    In addition, because the forming steps of the protection layers  208  and  210  are integrated with the inherent steps of a MOS process, the MOS process does not become more complicated. 
       Second Embodiment 
       [0041]      FIG. 5  depicts a top view of a composite structure including an STI structure and a protection layer thereon according to the second embodiment of this invention. FIG.  6  depicts a cross-sectional view of the composite structure of  FIG. 5  along line C-C′. In this embodiment, the protection layer is formed from an additional material layer never formed in the corresponding semiconductor device process of the prior art. 
         [0042]    Referring to  FIGS. 5-6 , a substrate  300  is provided with an STI structure  302  formed therein that defines active areas  303 . The STI structure  302  may include silicon oxide, and may be formed with any suitable process in the prior art. 
         [0043]    A protection layer  304  is formed on the flat surfaces of the STI structure  302 , including a material having a lower etching rate than that of the STI structure  302 , such as silicon nitride (SiN), silicon-rich silicon oxide or silicon oxynitride (SiON). To from the protection layer  304 , it is possible to form a base layer (not shown) as a precursor thereof over the entire substrate  300  and then pattern the same to remove the portions thereof not over the STI structure  302 . 
         [0044]    It is particularly noted that the protection layer  304  is formed immediately after the STI structure  302  is formed, so that the STI structure  302  is not damaged by subsequent etching or cleaning and can have a substantially flat surface. 
         [0045]    In other embodiments, the protection layer formed from an additional material layer may not be formed immediately after the STI structure is formed, because the protection layer can ensure the desired functions of the STI structure if only it is formed before the pre-cleaning step prior to the salicide process which would damage an unprotected STI structure badly. 
         [0046]    Because a protection layer is formed/disposed on the STI structure having a recess therein, it is possible to prevent deepening and extension of the recess in later etching and cleaning, so that the isolation effect of the STI structure is maintained. Further, because the protection layer prevents extension of the recesses in the STI layer, two neighboring contacts are prevented from being shorted. In addition, by integrating the forming steps of the protection layer with those of one or more other functional layers like a salicide block layer and/or a spacer, the semiconductor device process does not become more complicated. 
         [0047]    It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.

Technology Classification (CPC): 7