Source: http://www.google.com/patents/US6261873?dq=alibre+inassignee:alibre
Timestamp: 2014-10-23 05:40:09
Document Index: 569526524

Matched Legal Cases: ['art 200', 'art 200', 'art 200', 'art 200', 'art 200', 'art 400', 'art 400', 'art 400', 'art 400', 'art 400']

Patent US6261873 - Pedestal fuse - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA structure and method of fabricating a metallization fuse line is disclosed. The structure can be formed on a semiconductor substrate, including an insulator structure formed on the substrate, the insulator structure having an upper layer and a lower layer, the upper being thinner than the lower, the...http://www.google.com/patents/US6261873?utm_source=gb-gplus-sharePatent US6261873 - Pedestal fuseAdvanced Patent SearchPublication numberUS6261873 B1Publication typeGrantApplication numberUS 09/303,355Publication dateJul 17, 2001Filing dateApr 29, 1999Priority dateApr 29, 1999Fee statusLapsedAlso published asUS6455914, US6492207, US20010031516, US20010034084Publication number09303355, 303355, US 6261873 B1, US 6261873B1, US-B1-6261873, US6261873 B1, US6261873B1InventorsDennis P. Bouldin, Timothy H. Daubenspeck, William T. MotsiffOriginal AssigneeInternational Business Machines CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (8), Non-Patent Citations (2), Referenced by (12), Classifications (8), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetPedestal fuseUS 6261873 B1Abstract A structure and method of fabricating a metallization fuse line is disclosed. The structure can be formed on a semiconductor substrate, including an insulator structure formed on the substrate, the insulator structure having an upper layer and a lower layer, the upper being thinner than the lower, the insulator structure having a plurality of openings of varying depth, and a metal structure inlaid in the insulator structure, the metal structure having first and second portions and a third portion there between that is substantially more resistive than the first and second portions, the third portion having a thickness substantially similar to the thickness of the upper layer of the insulator structure. The upper layer includes a nitride, the lower layer includes an oxide and the metal structure includes copper. The fuse structure allows formation of �easy to laser delete� thin metal fuses within segments of thick metal lines. This applies to wiring layers formed from �high� melting temperature metals and those defined using a damascene process. For example, copper back end of line (Cu BEOL) damascene wiring, as used with CMOS can use the invention. The technique achieves high yield fusing for technologies that use thick wiring layers. The structure separates the thickness of the fuse segment from the remainder of the wiring line. The structure can be used with very thick, e.g., >1.2μ wiring and very thin, e.g., <0.5μ fuses.
What is claimed is: 1. A method for forming a thin pedestal fuse segment in a thick last metal (LM) wiring line, comprising the steps of:
(a) forming a last metal minus 1 (LM−1) wiring layer and an overlaying oxide inter layer dielectric (ILD) using conventional techniques; (b) depositing a layer of nitride using conventional techniques, wherein a thickness of said nitride layer is an approximate thickness desired for the thin pedestal fuse segment; (c) defining with a resist layer and mask the LM wiring line that will contain a fuse link, wherein said fuse link is not yet imaged; (d) etching said nitride layer and said oxide ILD, forming a thick line trench; (e) stripping said resist; (f) applying a new layer of resist and opening an image, defining said fuse link overlapping adjacent ends of an interrupted LM trench; (g) etching said nitride layer using an etchant; (h) stripping said new layer of resist; (i) applying another layer of resist and imaging and etching via contacts, wherein said via contacts will connect said LM to said LM−1 wiring layers; (j) stripping said another layer of resist; (k) filling said wiring trench with at least one metal; and (l) polishing to remove unwanted and excess metal, forming LM damascene fuse line having the thin pedestal fuse segment. 2. The method according to claim 1, wherein said oxide layer comprises silicon dioxide.
3. The method according to claim 1, wherein said nitride comprises silicon nitride.
4. The method according to claim 1, wherein said step (b) comprises at least one of a chemical vapor deposition (CVD), a physical vapor deposition (PVD), an evaporation, and a plating technique.
5. The method according to claim 1, wherein said step (g) comprises using an etchant that is relatively selective to said nitride.
6. The method according to claim 1, wherein said step (g) comprises using an etchant, wherein if said nitride layer is thin, selectivity is not required.
7. The method according to claim 1, wherein said step (k) comprises filling said wiring trench with copper.
8. The method according to claim 1, wherein said step (l) comprises using at least one of a chemical and a mechanical polishing technique.
These fuses are typically opened by applying a laser pulse of sufficient size, duration and power as to superheat and vaporize the metal forming the fuse. This superheating of the fuse and its vaporization fractures and blows away a portion of the overlying glassy protective layer creating a saucer shaped crater in the protective layer. When the protective layer ruptures, cracks can radiate outwardly causing additional damage such as breakage of, or the uncovering of, adjacent fuse elements. Such uncovering of the adjacent elements can cause subsequent corrosion and premature failure of the circuit. While fuses are typically opened using a laser, they may also be opened by passage of electrical current or exposure to an ion beam which ablates (or removes or sputters) away the fuse link.
The reader is referred to the following patents related to fuses including �Array Protection Devices and Fabrication Method,� U.S. Pat. No. 5,523,253, and �Array Fuse Damage Protection Devices and Fabrication Method,� U.S. Pat. No. 5,420,455, both to Richard A. Gilmour, et al. and of common assignee to this invention, the contents of which are incorporated herein by reference in their entireties.
Fuses are used in semiconductor chips to provide redundancy, electrical chip identification and customization of function. For designs having three (or more) layers of wiring, the fuses are typically formed from a segment of one of the wiring layers, e.g., the �last metal� (LM) or �last metal minus one� (LM−1) wiring layer. Fusing, i.e., the deletion of a segment of metal fuse line, is accomplished by exposing the segment of metal fuse line to a short, high intensity pulse of �light� from an infra-red (IR) laser. The metal line absorbs energy, melts and expands, and ruptures any overlain passivation. The molten metal then boils or vaporizes out of its oxide surroundings, disrupting line continuity and causing high electrical resistance. A �sensing� circuit is used to detect fuse segment resistance.
SUMMARY OF THE INVENTION The present invention includes a method for forming a thin pedestal fuse segment in a thick last metal (LM) wiring line, including the steps of forming a last metal minus 1 (LM−1) wiring layer and an overlaying oxide inter layer dielectric (ILD) using conventional techniques, depositing a layer of nitride using conventional techniques, wherein a thickness of the nitride layer is an approximate thickness desired for the thin pedestal fuse segment, defining with a resist layer and mask the LM wiring line that will contain a fuse link, wherein the fuse link is not yet imaged, etching the nitride layer and the oxide ILD, forming a thick line trench, stripping the resist, applying a new layer of resist and opening an image, defining the fuse link overlapping adjacent ends of an interrupted LM trench, etching the nitride layer using an etchant, stripping the new layer of resist, applying another layer of resist and imaging and etching via contacts, wherein the via contacts will connect the LM to the LM−1 wiring layers, stripping the another layer of resist, filling the wiring trench with at least one metal, and polishing to remove unwanted and excess metal, forming a LM damascene fuse line having the thin pedestal fuse segment.
In another embodiment of the invention, a method for forming a thin pedestal fuse segment in a last metal (LM) wiring line includes the steps of forming a last metal minus 1 (LM−1) wiring layer and an overlaying oxide inter layer dielectric (ILD) layer using conventional techniques, depositing a layer of nitride using conventional techniques, wherein a thickness of the nitride layer is an approximate thickness desired for the thin pedestal fuse segment, defining with a resist layer and mask the LM wiring line that will contain a fuse link, wherein the fuse link is not yet imaged, etching the nitride layer and the underlying oxide ILD, forming a thick wiring line trench, stripping the resist layer, applying a new layer of resist and opening an image over an interrupted segment etching selectively the oxide to form vias using an etch selective to the oxide, leaving exposed a nitride pedestal cap, etching selectively the nitride pedestal cap using an etch selective to the nitride, stripping the new layer of resist, filling the wiring line trench with at least one metal, and polishing to remove unwanted and excess metal, forming LM damascene fuse line having the thin pedestal fuse segment.
In another embodiment of the invention, a metallization structure formed on a semiconductor substrate, includes an insulator structure formed on the substrate, the insulator structure having an upper layer and a lower layer, the upper layer being thinner than the lower layer, the insulator structure having a plurality of openings therein of varying depth, and a metal structure inlaid in the insulator structure, the metal structure having first and second portions and a third portion there between that is substantially more resistive than the first and second portions, the third portion having a thickness that is substantially similar to the thickness of the upper layer of the insulator structure. In an embodiment of the invention, the upper layer includes a nitride layer and the lower layer includes an oxide layer. In another embodiment of the invention, the metal structure includes copper.
An advantage of the present invention is that the claimed fuse structure allows formation of �easy to delete� thin metal fuses within segments of thick metal lines. The claimed structure is particularly applicable to wiring layers formed from �high� melting temperature metals and those defined using a damascene process.
The present invention provides an integrated path to achieve high yield fusing for technologies that use thick wiring layers or wiring layers comprised of high melting temperature metals. The structure of the present invention separates the thickness of the fuse segment from the remainder of the wiring line. The structure is compatible with thick (such as, e.g., 0.8μ), very thick (such as, e.g., greater than 1.2μ wiring) and very thin (such as, e.g., less than 0.5μ fuses). The present invention is particularly valuable for technologies using damascene to define wiring levels. One example of applicable technology is in development of central processing unit (CPU) chip sets for CMOS semiconductor integrated circuit chips.
Overview of Present Invention Laser delete of metal fuses becomes more difficult as the thickness of the metal fuse increases. A section of last metal (LM) line is formed which is left intact in an unblown fuse and is removed in a blown fuse, in order to provide a high resistance. A fuse is blown by shining an infrared (IR) laser on the metal line. To make the line high resistance, all the metal of the fuse must be removed. This becomes difficult as the fuse gets thick, i.e., becomes deeper and deeper, requiring a higher energy IR laser. After sufficient depth, the metal line can not be removed without seriously damaging surrounding and underlaying structures. This invention provides a structure which creates a locally, thin, easy-to-delete line section and provides for the use of very thick wiring everywhere else on the circuit, chip or wafer. The present invention enables the use of very thick wiring to carry large amounts of current about the chip from one area to another, while still providing functional fuses, i.e. functional at low laser energies, such that no damage is sustained by surrounding circuitry.
The invention includes a metal wiring line containing a fuse link segment where the fuse link segment is thinner than the adjacent fixed wiring line of which it is a part. The thickness of the fuse link segment can be adjusted independently of the remainder of the wiring line. Fuse link horizontal dimensions can be adjusted independently of the wiring line dimensions if desired. The present invention is particularly useful for back end of line (BEOL) wiring structures, where a �thick� wire option is employed.
It will be apparent to those skilled in the art, that the present invention is not restricted to LM or LM−1 wiring layers, but can be used at any wiring layer.
1. forming an LM−1 wiring layer and its overlaying dielectric layer using conventional techniques;
2. depositing a layer of silicon nitride (i.e. referred to as the �nitride layer�) using conventional techniques, such as, e.g., chemical vapor deposition (CVD), wherein the thickness of the silicon nitride layer is the approximate thickness desired for the �thin� fuse segment that will be formed in the last metal (LM) wiring line, e.g. less than or equal to 0.5μ;
3. defining the LM wiring line that will contain the fuse link, but not imaging the fuse link at this time;
4. etching the nitride and an underlying interlayer dielectric (ILD) (such as, e.g., silicon dioxide) (i.e. referred to as �the oxide layer�) to form a thick line trench, typically of greater than or equal to (>=) 0.8μ; stripping the resist;
7. applying a new layer of resist and image and etching the via contacts that will connect LM to LM−1 wiring layers; stripping the new layer of resist; and
In an alternative embodiment, after defining the trench which will hold the conductor line (i.e., step 4 above), applying a new layer of resist (step 5) and opening images defining the vias and fuse link. Specifically, using an etch selective to oxide the technique first etches the vias, then using an etch selective to nitride the technique creates the shallow trench for the fuse link. The resist can then be stripped and the wiring trench can then be filled with one or more metals. The preceding alternative process is described further with reference to FIGS. 3A-F and 4.
FIG. 2 begins with step 202 which can continue immediately with step 204. In step 204, an interrupted fuse line is formed including a resist layer, a nitride layer, an oxide layer and a last metal minus one (LM−1) layer. Specifically, interrupted fuse line is formed by placing a resist layer over the previously deposited nitride layer. The nitride layer can include a material such as, e.g., silicon nitride, deposited using conventional methods such as, e.g., chemical vapor deposition (CVD), over the previously deposited oxide layer. The oxide layer can include a material such as, e.g., silicon dioxide, deposited using a conventional method such as, e.g., chemical vapor deposition(CVD) on the previously deposited LM−1 layer. The thickness of the silicon nitride layer can be selected according to the approximate thickness desired for the resulting �thin� fuse segment (see FIG. 1G, below) which is to be formed in the last metal (LM) wiring line. In one embodiment, the desired thickness of the �thin� fuse segment can be, e.g., 0.5μ or less. In another embodiment, the desired fuse segment can be, e.g., 0.8μ or less. In yet another embodiment, the desired fuse segment can be, e.g., 0.3μ or less. Fuse thicknesses can be adjusted to provide advantageous chip yields. Table 1, below, illustrates exemplary fuse thicknesses and some observed fuse yields associated with certain example fuse segment thicknesses. An example of the structure formed by step 204 is depicted in FIG. 1A.
Fuse Yield
FIG. 1A illustrates a semiconductor structure including resist segments 102 a, 102 b and 102 c formed on a thin upper nitride layer 104 which overlays an inter layer dielectric (ILD) oxide layer 106 which in turn overlays last metal minus 1 (LM−1) layer segments 108 a and 108 b. From step 204, flowchart 200 can continue with step 206. In step 206, the nitride layer and oxide layer can be etched to create a �line� trench, and the resist layer can be stripped. The structure formed by step 206 is depicted in FIG. 1B.
FIG. 1B illustrates the semiconductor structure of FIG. 1A following etching of the nitride and oxide layers 104 and 106, yielding oxide layer 106 a including exemplary line trenches and pedestals. Nitride 104 is etched leaving nitride segments 104 a, 104 b and 104 c remaining capping the pedestals of oxide layer 106 a, formed by stripped resist segments 102 a, 102 b and 102 c. LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 a. From step 206, flowchart 200 can continue with step 208. In step 208, resist can be applied and an image can be opened using a mask or reticle over resist segments and interrupted center pedestal oxide segment, leaving uncovered the interrupted center pedestal oxide segment and covering the other oxide pedestal portions where the nitride layer will be retained. The resulting structure of the material is illustrated in FIG. 1C.
FIG. 1C illustrates the semiconductor structure of FIG. 1B following application of resist segments 110 a and 110 b and opening an image mask over interrupted center oxide segment of oxide 106 a having nitride segment cap 104 b, leaving resist segments 110 a and 110 b, protecting nitride segment caps 104 a and 104 c, respectively. LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 a. Photoresist can be dispensed with a wafer structure stationary or rotating. A uniform resist thickness is preferred.
FIG. 1D illustrates the semiconductor structure of FIG. 1C following etching of interrupted nitride cap segment 104 b of oxide 106 a, and stripping of resist segments 110 a and 110 b, leaving exposed the center pedestal portion of oxide 106 b and nitride caps 104 a and 104 c. LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 b. From step 210, flowchart 200 can continue with step 212. In step 212, resist can be applied and an image can be opened using a mask for defining vias to the LM−1 layer forming resist segments leaving uncovered the intended locations of the vias and covering the center pedestal portion of the oxide and the two nitride capped pedestals. The resulting structure formed by step 212 is illustrated in FIG. 1E.
FIG. 1E illustrates the semiconductor structure of FIG. 1D following application of resist segments 112 a, 112 b and 112 c over pedestals portions of oxide 106 b including nitride cap segments 104 a and 104 c and opening an image mask so as to leave uncovered by resist portions of oxide 106 a intended as locations of vias to LM−1 segments 108 a and 108 b. LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 b. From step 212, flowchart 200 can continue with step 214. In step 214, the oxide segments intended as locations of vias to LM−1 can be selectively etched away and the resist segments can then be stripped away, leaving a structure include vias and line trenches ready for a damascene metallization fill. Various etching techniques can be used including, e.g., wet etching and dry etching. Wet etching can use various mixtures of hydrofluoric acid and water (e.g., 10:1, 6:1, 100:1), and can include a buffering agent such as ammonium fluoride for a slower, more controlled etch rate. Although relatively inexpensive, wet etching can also lead to severe undercutting since it is an isotropic process, i.e. proceeding at nearly equal rates in all directions, which can make it impractical. To avoid encroachment, dry, or plasma etch technology, using, e.g., a glow discharge to ionize an inert gas (i.e. reactive ion etching (RIE)physical sputtering) can be used to set up very anisotropically (i.e. directional) etched features, providing for higher circuit densities. When multiple layers are involved in dry etching process, such as silicon nitride over silicon dioxide, it is important to know the relative etch rates of the two materials in the available etchants. This �selectivity� will determine if significant etching of underlying layers will occur. Plasma etch processes, since they are basically chemical by nature exhibit better selectivity as compared to RIE physical sputtering processes. To etch the oxide layer using plasma etch CF4, CHF3 and NF3 gases can be used, for example, with an etch rate of greater than 5000 angstrom per minute. The resulting structure formed by step 214 is illustrated in FIG. 1F.
FIG. 1F illustrates the semiconductor structure of FIG. 1E following etching of oxide 106 b to form vias therein. FIG. 1F depicts oxide 106 b with etched vias yielding oxide portions 106 c, 106 d and 106 e. Oxide portions 106 c and 106 e have nitride segments 104 a and 104 c capping them, respectively. And center pedestal 106 d is now ready for damascene fill to form a thin line fuse of thickness approximately equal to original nitride segment 104 b. The vias formed by etching in step 214 of oxide 106 b provide access to LM−1 segments 108 a and 108 b as shown.
From step 214, flowchart 200 can continue with step 216. In step 216, the trench formed by the preceding steps can be filled with one or more layers of metal or barrier layers followed by metal and can be polished using a chemical, mechanical polishing process to form a last metal (LM) damascene fuse line link having a thin region of thickness approximately equal to the nitride layer thickness. Metal is used in semiconductor processing for creating low resistance paths. Barrier layers are used to prevent metal interaction with the surrounding dielectric. Metal and barrier layers can be put down by, e.g., the chemical vapor deposition(CVD) process, physical vapor deposition (PVD) sputtering process, evaporation, and plating. For example, using CVD, WF6 can be used to deposit tungsten (W). Copper can be deposited using a sputtering process or plating. Physical vapor deposition can be done by an evaporation metallization process and a sputtering deposition process. Copper deposition can include depositing Ta or TaN as a liner or barrier layer between Cu and Si. The resulting structure formed by step 216 is illustrated in FIG. 1G. From step 216, flowchart can immediately end with step 218.
FIG. 4 begins with step 402 which can continue immediately with step 404. In step 404, an interrupted fuse line is formed including a resist layer, a nitride layer, an oxide layer and a last metal minus one (LM−1) layer. Specifically, interrupted fuse line is formed by placing a resist layer over the previously deposited nitride layer. The nitride layer can include a material such as, e.g., silicon nitride, deposited using conventional methods such as, e.g., chemical vapor deposition (CVD), over the previously deposited oxide layer. The oxide layer can include a material such as, e.g., silicon dioxide, deposited using a conventional method such as, e.g., chemical vapor deposition(CVD) on the previously deposited LM−1 layer. The thickness of the silicon nitride layer can be selected according to the approximate thickness desired for the resulting �thin� fuse segment (see FIG. 3F, below) which is to be formed in the last metal (LM) wiring line. In one embodiment, the desired thickness of the �thin� fuse segment can be, e.g., 0.5μ or less. In another embodiment, the desired fuse segment can be, e.g., 0.8μ or less. In yet another embodiment, the desired fuse segment can be, e.g., 0.3μ or less. Certain thicknesses can provide advantageous chip yields. Table 1, above, illustrates exemplary fuse thicknesses and some observed fuse yields associated with certain example fuse segment thicknesses. An example of the structure formed by step 404 is depicted in FIG. 3A.
FIG. 3A illustrates a semiconductor structure including resist segments 302 a, 302 b and 302 c formed on a thin upper nitride layer 304 which overlays an inter layer dielectric (ILD) oxide layer 306 which in turn overlays last metal minus 1 (LM−1) layer segments 308 a and 308 b. From step 404, flowchart 400 can continue with step 406. In step 406, the nitride layer and oxide layer can be etched to create a �line� trench, and the resist layer can be stripped. The structure formed by step 406 is depicted in FIG. 3B.
FIG. 3B illustrates the semiconductor structure of FIG. 3A following etching of the nitride and oxide layers 304 and 306, yielding oxide layer 306 a including exemplary line trenches and pedestals. Nitride 304 is etched leaving nitride segments 304 a, 304 b and 304 c remaining capping the pedestals of oxide layer 306 a, formed by stripped resist segments 302 a, 302 b and 302 c. LM−1 segments 308 a and 308 b remain overlaid by the oxide ILD layer 306 a. From step 406, flowchart 400 can continue with step 408. In step 408, resist can be applied and an image can be opened using a mask or reticle over resist segments and interrupted center pedestal oxide segment, leaving uncovered the interrupted center pedestal oxide segment and covering the other oxide pedestal portions where the nitride layer will be retained. The resulting structure of the material is illustrated in FIG. 3C.
FIG. 3C illustrates the semiconductor structure of FIG. 3B following application of resist segments 310 a and 310 b and opening an image mask over interrupted center oxide segment of oxide 306 a having nitride segment cap 304 b, leaving resist segments 310 a and 310 b, protecting nitride segment caps 304 a and 304 c, respectively. LM−1 segments 308 a and 308 b remain overlaid by the oxide ILD layer 306 a. From step 408, flowchart 400 can continue with step 410. In step 410, the technique can selectively etch the exposed oxide layer forming vias to the LM−1 layer, leaving exposed the nitride cap segment protecting the center pedestal oxide segment, and leaving covered the two other pedestal portions of the oxide and their two nitride caps. The resulting structure formed by step 410 is illustrated in FIG. 3D.
FIG. 3D illustrates the semiconductor structure of FIG. 3C following selective etching of oxide 306 a forming vias to LM−1 segments 308 a and 308 b. Resist segments 310 a and 310 b protect pedestal portions of oxide 306 b and 306 d and nitride cap segments 304 a and 304 c, and LM−1 segments 308 a and 308 b are overlaid by the oxide ILD layer segments 306 b and 306 d. From step 410, flowchart 400 can continue with step 412. In step 412, the center nitride cap segment over the center interrupt oxide pedestal can be selectively etched away and the resist layer can then be stripped away. The center nitride cap segment, if sufficiently thin, can be etched without a selective etchant. It will be apparent to those skilled in the art that the oxide layer segments 306 b and 306 d could be etched if not covered by resist segments 310 a and 310 b, as shown in FIG. 3E. The resulting structure formed by step 412 is illustrated in FIG. 3E.
FIG. 3E illustrates the semiconductor structure of FIG. 3D following etching of interrupted nitride cap segment 304 b of center pedestal oxide 306 c. LM−1 segments 308 a and 308 b remain overlaid by the oxide ILD layer segments 306 b and 306 c. From step 412, flowchart 400 can continue with step 414. In step 414, the resist is stripped away, including resist segments 310 a and 310 b, leaving the structure ready for damascene fill. The resulting structure includes vias and line trenches ready for a damascene metallization fill. The resulting structure formed by step 414 after damascene filling is illustrated in FIG. 3F.
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