Patent Document

RELATED PATENT APPLICATION 
       [0001]    This application claims priority to commonly owned U.S. Provisional Patent Application No. 62/302,944; filed Mar. 3, 2016; which is hereby incorporated by reference herein for all purposes. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to semiconductor manufacturing and the teachings of the present disclosure may be embodied in a semiconductor chip with an interconnect monitor. 
       BACKGROUND 
       [0003]    Integrated circuits grow increasingly complex and the associated manufacturing processes are more complicated. The complications result in lower yield and higher cost for IC devices. New IC designs are reduced in size and yet the number of elements in a given chip is increased. The increasing complexity requires an increased number of connections between elements as well. 
         [0004]    During normal IC manufacturing processes, various layers of semiconductor material, metals, insulators, and other materials are deposited, patterned, and/or etched to create electronic circuitry between circuit elements. The circuit connections may be horizontal or vertical, considered in relation to the plane of the underlying substrate, or chip. Vertical connections, called vias, may connect two metal layers, one metal layer and a semiconductor layer, or other combinations. In comparison to horizontal connections, vias tend to be very small and, therefore, more prone to failure if there are any defects or irregularities in a manufacturing process. 
         [0005]    A faulty via may interrupt or change the flow of electricity in the circuitry of an IC device. In particular, a faulty via may not fail upon completion of the circuit, but only after degrading over time in use. An IC device may pass any quality control checks during the manufacturing process and still fail prematurely. U.S. Pat. Nos. 7,919,973 and 8,878,183 describe a so-called contact/via test vehicle which facilitates a monitoring process in the semiconductor fabrication of integrated circuits, whose products may encompass a myriad application in various technical fields. These two patents are hereby incorporated by reference in their entirety. 
       SUMMARY 
       [0006]    Since the introduction of the contact/via test vehicle, a number of needed improvements have been identified. For example, the original purpose of the contact/via test chip was to detect open interconnects, but it would be advantageous to also detect interconnect shorts. The teachings of the present disclosure may be embodied in a semiconductor chip with an interconnect monitor. 
         [0007]    Some embodiments may include arrays of diodes on the semiconductor chip; each diode with a stack of vertical interconnects and metal contacts, the stack and the diode connected in series and control mechanisms for addressing the diodes. The control mechanisms may include first inverters for applying either a high or a low voltage to columns of the diode stacks, connected at one end of each diode stack. Each first inverter may include reverse logic receiving a reverse logic signal and configured to invert a logic signal fed to the device for applying a relatively high or low voltage and second inverters for applying either a high or a low voltage to rows of the diode stack in the one of the plurality of arrays, connected at a second end of said diode stack, wherein each second inverter comprises reverse logic receiving an inverted reverse logic signal and configured to invert a logic signal fed to the device for applying a relatively high or low voltage. 
         [0008]    In some embodiments, the diodes are formed by a first p-type semiconductor deposition into an n-type well arranged within a p-type substrate. The semiconductor chip may include electrical connections for each diode, the electrical connections each formed by of a second p-type semiconductor deposition into the p-type substrate and a plurality of p-n-p parasitic transistors comprised of said electrical connections, said p-type substrate, said n-type well, and said first p-type semiconductor depositions. 
         [0009]    In some embodiments, the parasitic transistors share a physical location with said diodes, and said parasitic transistors and said diodes are connected in parallel. 
         [0010]    In some embodiments, a plurality of p-type semiconductor regions are deposited adjacent to each said diode, and the p-type semiconductor regions are connected to the terminal of a transistor adjacent to the diode in the substrate of the chip. 
         [0011]    In some embodiments, the p-type semiconductor regions adjacent to each diode in an array are connected. 
         [0012]    In some embodiments, the p-type semiconductors regions are connected to a first voltage, said voltage having a lower potential than said high voltage applicable to a column of diode and stack combinations. 
         [0013]    In some embodiments, the plurality of control mechanisms further comprises transistors for disconnecting voltage sources to allow unselected diodes from the plurality of diodes to float. 
         [0014]    Some embodiments may comprise a semiconductor chip for process monitoring of semiconductor fabrication. The chip may include a plurality of arrays disposed on the semiconductor chip. Each array may include a plurality of diodes, each diode formed in the chip and associated with a stack including a plurality of vertical interconnects and metal contacts, each one of the plurality of diodes and the associated stack connected in series to form a diode stack combination. The chip may further include a plurality of control mechanisms for addressing the plurality of diodes. The control mechanisms may include a device for applying a relatively high or low voltage to one or more columns of the diode stack combinations in a given array, connected at a first end of said diode stack combination; a device for applying a relatively high or low voltage to one or more rows of the diode stack combinations in a given array, connected at a second end of said diode stack combination, and a current meter measuring a current through the diode stack combinations. 
         [0015]    In some embodiments, the control mechanisms comprise inverters. 
         [0016]    Some embodiments may include a plurality of electrical connections for each diode, wherein the diodes comprise a p-n transition within said semiconductor chip formed by a first p-type semiconductor deposition into an n-type well arranged in a p-type substrate; the electrical connections including deposition of a second p-type semiconductor into the p-type substrate; and the plurality of arrays further comprising a plurality of p-n-p parasitic transistors comprising the plurality of electrical connections, the p-type substrate, the n-type well, and the first p-type semiconductor depositions. 
         [0017]    In some embodiments, each parasitic transistor shares a physical location with an associated diode, and the parasitic transistors and the diodes are connected in parallel. 
         [0018]    Some embodiments may include a plurality of p-type semiconductor regions arranged adjacent to each diode, the p-type semiconductor regions connected to the terminal of a transistor adjacent to the diode in the substrate of the semiconductor chip. 
         [0019]    In some embodiments, the p-type semiconductor regions adjacent to each diode in a given array are connected to each other. 
         [0020]    Some embodiments may include the p-type semiconductors connected to a first voltage with a lower potential than the relatively high voltage applicable to a column of diode and stack combinations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is a drawing showing an example system which may be used to monitor a semiconductor manufacturing process by testing electronic circuitry on a semiconductor chip, according to teachings of the present disclosure. 
           [0022]      FIG. 2  is a drawing showing an example electrical circuit including an array of diodes according to the teachings of the prior disclosures. 
           [0023]      FIG. 3  is a drawing of a portion of diode stack combination showing a cross-section of a diode and an associated stack according to the teachings of the prior disclosures. 
           [0024]      FIG. 4  is an isometric drawing showing a portion of the diode stack combination from  FIG. 3  at an angle for the sake of clarity. 
           [0025]      FIG. 5  is a drawing showing an example electrical circuit including an array of diodes according to the teachings of the present disclosure. 
           [0026]      FIG. 6  is an isometric drawing showing a portion of diode stack combination at an angle for the sake of clarity. 
           [0027]      FIG. 7  is a drawing showing a schematic of various layers in comparison between the prior disclosures and the teachings of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0028]      FIG. 1  is a drawing showing an example system  100  which may be used to monitor a semiconductor manufacturing process by testing electronic circuitry on a semiconductor chip, according to teachings of the present disclosure. System  100  may include a semiconductor manufacturing process  101  to be monitored. A semiconductor wafer  102  may include a plurality of chips  103  created by the process  101 . In some embodiments, each chip  103  may include a plurality of diodes arranged in an addressable array  200  (shown in more detail in  FIG. 2 ). Each diode may have an associated stack of vertical interconnects and metal contacts. 
         [0029]    System  100  may include a probing tester  104  to take data related to each stack for comparison against a manufacturing specification. In some embodiments, tester  104  may test  10  different chips  103  in parallel. In some embodiments, tester  104  may test all ten chips  103  at the same time. In some embodiments, tester  104  may test the same stack on all ten chips  103  at the same time. Tester  104  yields anomaly data  105 , including for example, data sets for measured anomalies, including a measurement and a location of the measurement. Anomalies may include current measurements or associated resistance calculations for vias on the wafer. For example, an “open” via may not conduct any current and/or may show a very high resistance. As another example, a short circuit between contacts may conduct too much current and/or show a very low resistance. In some embodiments, tester  104  may identify any elements that do not meet predefined criteria for current and/or resistance. 
         [0030]    Tester  104  may also yield parametric information  106  comprising details of the tests as conducted. Analysis of the parametric information  106  in light of the information  105  may detect and/or identify possible problems in the tested manufacturing processes. 
         [0031]    A test chip as contemplated in the present disclosure may be used to detect open interconnects as well as interconnect short circuits or shorts. The prior test vehicles used a memory mapped diode array to detect open circuits in the formation of contacts and vias. The various embodiments of the present disclosure use a “reversible decoder” to switch the polarity of the decoders to check for shorts. This capability coupled with layout techniques make this test vehicle more sensitive to inadvertent shorts in metal and contacts. Further, this can all be accomplished while still maintaining the ability to electrically isolate the defect. 
         [0032]      FIG. 2  is a drawing showing an example electrical circuit  200  including an array of diodes  201  according to the teachings of the prior disclosures. For purposes of illustration, so the diodes  201  may be addressed as an array, the drawing of circuit  200  shows the diodes  201  laid out and connected as a two-dimensional array with columns and rows. Each diode  201  in the array of diodes has an associated stack  202  of vertical interconnects and metal contacts, which may include a polysilicon diode covered with a silicide layer (discussed in detail in relation to  FIG. 3 ). 
         [0033]    Electrical circuit  200  may include a column inverter  203  connected to each column  209  of diodes  201  at the respective cathodes. Column inverters  203  may act as a control mechanism to select a column  210  for testing the diode  201  and associated stack  202 . A voltage source  205  may be connected to all the column inverters  203 . In some embodiments, voltage source  205  may be four volts. 
         [0034]    Electrical circuit  200  may include a row inverter  204  connected to each row  210  of diodes  201  at the respective anodes. Row inverters  204  may act as a control mechanism to select a row  210  for testing the diode  201  and associated stack  202 . A voltage sink  206  may be connected to all the row inverters  204 . In some embodiments, voltage sink  206  may be one volt. 
         [0035]    Each column inverter  203  may include inputs allowing selection of voltage source  205  (a relatively high voltage) or voltage source  207  (a relatively low voltage). Voltage source  207  may be ground. Each row inverter  204  may include inputs for selecting whether the row inverter  204  will route the voltage sink  206  or a high voltage  208 . In some embodiments, high voltage  208  may be five volts. Any given stack  202  of vertical interconnects and contacts will then be in series with the column inverter  203  and a diode  201 . 
         [0036]      FIG. 3  is a drawing of a portion of diode stack combination  300  showing a cross-section of a diode  201  and an associated stack  202 . To form diode  201 , a p +  region  301  is deposited into an N-Well  302 . This arrangement forms the basic structure of a p-n junction of a diode  201 . The N-Well  302  may itself be arranged in a p +  substrate  305 . Above this diode are deposited various layers of connections, for example various contacts, vias, and metal interconnects. As shown in  FIG. 3 , contact  320  connects diode  201  to a first metal layer comprising wire  325 . The first metal layer may also comprise a second wire  325 ′ coupled to wire  325  through vias  303  and a horizontal interconnect wire  310 . Horizontal interconnect wire  310  may comprise a salicided polysilicon wire  312 / 314  comprising polysilicon sections  312  and  314  on top of which a silicide layer  316  is formed. The silicide layer may comprise TiS 2 , CoSi 2 , NiSi, WSi 2 , or any other suitable material. 
         [0037]    In some embodiments, the polysilicon wire portion may be formed by two differently doped polysilicon sections  312  and  314 . Section  314  may be p +  doped and section  312  may be n +  doped. The two sections divide the horizontal polysilicon wire into two sections of approximately equal length as shown in  FIG. 3 . In some embodiments, sections  312  and  314  may not have equal lengths, but any length appropriate to form a functional diode under layer  316 . As described, sections  312  and  314  are complementary doped polysilicon forming a reverse biased diode within the poly interconnect  310 . The silicide layer  316  if properly formed short circuits the diode. In such embodiments, the diode formed by sections  312  and  314  only becomes active if the silicide layer  316  is improperly formed. 
         [0038]    Vias  303  between connections  304  form the vertical stack  202 . The entire stack  202  is electrically connected to horizontal wire  310 . In the embodiment shown, vertical stack  202  is connected above the n +  doped section  312 . Another via  303  located above the p +  doped section connects the polysilicon wire  310  to metal layer  325 . At this point, if silicide layer  316  is improperly formed, the two sections  312  and  314  form a reverse biased diode and force an open circuit as compared to a conventional uniformly doped polysilicon layer that would merely have a reduced resistance if the overlaying polysilicide layer is improperly formed. The open circuit caused by the reversed biased diode can be easily detected by a test machine as described in relation to  FIG. 1 . The diode formed by sections  312  and  314  is in the opposite orientation with respect to current flow in comparison to the decode diode  201  formed by p +  region  301  is deposited into an N-Well  302 . Both diodes may be reversed, but if one is reversed, both must be. 
         [0039]    In some embodiments, the stack  202  of connections  303  and  304  formed by the various layers may be used for monitoring the manufacturing process of the interconnect layers. In some embodiments, the stack  202  may only include via  303  and metal wire  325 ′ or may include only a single connecting via  303  or metal contact. The connecting structure coupled to the silicide layer  316  above the n +  doped section  312  may have a variety of forms without departing from the scope of the present disclosure. 
         [0040]    As shown in  FIG. 3 , stack  202  may include multiple wires  304  and connecting vias  303  connected to the diode  201  through the horizontal interconnect  310  and contact  320 , serving as a terminal for the cathode of diode  201 . In some embodiments, by depositing the N-Well  302  into a P-Well  305  substrate, a parasitic PNP bipolar transistor is formed. To access the function of this transistor, an addition P +  region  306  may be deposited into substrate  305  to provide a connection. Some embodiments include oxide regions  330  to further separate the various active regions from each other. 
         [0041]      FIG. 4  is an isometric drawing showing a portion of diode stack combination  300  at an angle for the sake of clarity. The elements shown therein correspond to the elements shown in  FIG. 3 . The metal surrounds are connected to the row decoder through the N-Well  302 . A forward path may be isolated through each diode to identify poorly formed or incomplete contacts and/or vias. 
         [0042]      FIG. 5  is a drawing showing an example electrical circuit  500  including an array of diodes  501  according to the teachings of the present disclosure. For purposes of illustration, so the diodes  501  may be addressed as an array, the drawing of circuit  500  shows the diodes  501  laid out and connected as a two-dimensional array with columns and rows. Each diode  501  in the array of diodes has an associated stack  502  of vertical interconnects and metal contacts, which may include a polysilicon diode covered with a silicide layer as discussed in relation to  FIG. 3 . 
         [0043]    Electrical circuit  500  may include a column inverter  503  connected to each column  509  of diodes  501  at the respective cathodes. Column inverters  503  may act as a control mechanism to select a column  510  for testing the diode  501  and associated stack  502 . A voltage source  505  may be connected to the anode of each of the column inverters  503 . In some embodiments, voltage source  505  may be three point three (3.3) volts. 
         [0044]    Electrical circuit  500  may include a row inverter  504  connected to each row  510  of diodes  501  at the respective cathodes. Row inverters  504  may act as a control mechanism to select a row  510  for testing the diode  501  and associated stack  502 . A voltage supply  506  may be connected to all the row inverters  504 . In some embodiments, voltage supply  506  may be zero volts. 
         [0045]    Each column inverter  503  may include inputs allowing selection of voltage source  505  (a relatively high voltage) or voltage source  507  (a relatively low voltage). Voltage source  507  may be ground. Each row inverter  504  may include inputs for selecting whether the row inverter  504  will route the voltage supply  506  or a high voltage  508 . In some embodiments, high voltage  508  may be five volts. Any given stack  502  of vertical interconnects and contacts will then be in series with the column inverter  503  and a diode  501 . 
         [0046]    In contrast with circuit  200  described above, circuit  500  may include additional components comprising a reversible decoder to switch the polarity of the decoders. In the original polarity, circuit  500  allows testing for open circuits. Once the polarity is reversed, circuit  500  may be similarly used to check for inadvertent short circuits in metal layers or contacts. The techniques used to isolate the defect, including identifying the diode/connection stack by row and column remain effective. In this context, transistor  516  and  517  may be present to disconnect power from voltage source  505  to the columns  509  and voltage source  506  from rows  510 . 
         [0047]    For example, circuit  500  includes metal surrounds  515  for each contact/via stack  502 . The details of metal surrounds  515  are more clear in  FIG. 6  and will be discussed in that context. The electrical pathway defined through metal surrounds  515  are part of the reverse polarity circuit. The metal surrounds  515  are each connected to the respective row decoder  504 . As with the prior circuit, a forward path may be isolated through each diode to identify poorly formed or incomplete contacts and/or vias. In addition, however, a reverse path is now available to look for via-to-metal shorts and/or metal-to-metal shorts in an isolated stack. To complete the reversal, XOR gates  512 , NOT gate  513 , and additional components may be applied. For example, disconnecting power from sources  505  and  506  with transistors  516  and  517  allows the unselected rows and columns to float. That is, the sources are isolated and cannot drive the stacks. As a result, unrelated shorts will not interfere with the selected row/column. 
         [0048]      FIG. 6  is an isometric drawing showing a portion of diode stack combination  600  at an angle for the sake of clarity. To form the diode  501 , a p +  region is deposited into an N-Well. This arrangement forms the basic structure of a p-n junction of a diode  501 . The N-Well may itself be arranged in a p +  substrate  505 . Above this diode are deposited various layers of connections, for example various contacts, vias, and metal interconnects. As shown in  FIG. 6 , contact  520  connects diode  501  to a first metal layer comprising wire  525 . The first metal layer may also comprise a second wire  525 ′ coupled to wire  525  through vias  503  and a horizontal interconnect wire  510 . Horizontal interconnect wire  510  may comprise a salicided polysilicon wire with sections on top of which a silicide layer is formed, as discussed in relation to  FIG. 3 . The silicide layer may comprise TiS 2 , CoSi 2 , NiSi, WSi 2  or any other suitable material. 
         [0049]    In some embodiments, the polysilicon wire portion may be formed by two differently doped polysilicon sections. The first section may be p +  doped and the second section may be n +  doped. The two sections divide the horizontal polysilicon wire into two sections of approximately equal length. In some embodiments, the two sections may not have equal lengths, but any length appropriate to form a functional diode under layer. As described, the two sections are complementary doped polysilicon forming a reverse biased diode within the poly interconnect. The silicide layer, if properly formed, short circuits the diode. In such embodiments, the diode formed only becomes active if the silicide layer is improperly formed. 
         [0050]    Vias  503  between connections  504  form the vertical stack. The entire stack is electrically connected to horizontal wire. In the embodiment shown, the vertical stack is connected above the n +  doped section. Another via  503  located above the p +  doped section connects the polysilicon wire  510  to metal layer  525 . At this point, if the silicide layer is improperly formed, the reverse biased diode forces an open circuit as compared to a conventional uniformly doped polysilicon layer that would merely have a reduced resistance if the overlaying polysilicide layer is improperly formed. The open circuit caused by the reversed biased diode can be easily detected by a test machine as described in relation to  FIG. 1 . The diode formed is in the opposite orientation with respect to current flow in comparison to the decode diode  501  formed by the p +  region deposited into an N-Well. Both diodes may be reversed, but if one is reversed, both must be. 
         [0051]    In some embodiments, the stack of connections  503  and  504  formed by the various layers may be used for monitoring the manufacturing process of the interconnect layers. In some embodiments, the stack may include multiple vias  503  and metal wire  525 ′ or may include only a single connecting via  303  or metal contact. The connecting structure coupled to the silicide layer above the n +  doped section may have a variety of forms without departing from the scope of the present disclosure. 
         [0052]    As shown in  FIG. 6 , the stack may include multiple wires  504  and connecting vias  503  connected to the diode  501  through the horizontal interconnect  510  and contact  520 , serving as a terminal for the cathode of diode  501 . In some embodiments, by depositing the N-Well into a P-Well substrate, a parasitic PNP bipolar transistor is formed. To access the function of this transistor, an addition P +  region may be deposited into substrate  305  to provide a connection. Some embodiments include oxide regions to further separate the various active regions from each other. 
         [0053]    The metal surrounds  515  are each connected to the respective row decoder  504  through an N-Well. When the reverse polarity is engaged, the reverse path will identify via-to-metal and metal-to-metals shorts using the test apparatus of  FIG. 1 . 
         [0054]      FIG. 7  shows a comparison of the conventional cells and the new cells and associated metal density. Row A shows layers M 1 -M 4  corresponding to diode/stack/metal surrounds  600  of  FIG. 6  and Row B shows layers M 1 -M 4  of  FIG. 3 .

Technology Category: 5