Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a division of U.S. application Ser. No. 10/816,959, filed on Apr. 5, 2004 which is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2003-430387, filed on Dec. 25, 2003, the entire contents of which are incorporated herein by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a method for fabricating a semiconductor device, more specifically a method for fabricating a semiconductor device including the step of processing a lower layer by a multilayer resist process. 
         [0003]    As semiconductor devices are larger-scaled and more integrated, patterns are increasingly downsized. The downsizing of semiconductor devices is realized by shortening the light source wavelength of exposure systems used in the photolithography. Presently, as the light source, argon fluoride (ArF) excimer lasers of a 0.193 μm-wavelength are widely used. 
         [0004]    The photoresist film used in the photolithography using ArF excimer laser (ArF resist film) does not have sufficient etching selectivity with respect to the constituent materials of the semiconductor devices, so that it is difficult to accurately process lower layers with a single layer of the ArF resist film as the mask. 
         [0005]    As a process which solves this difficulty, a multilayer resist process is developed. In the multilayer resist process, the resist film is formed of a multilayer so as to enhance the function as a mask material for the lower film processing to thereby precisely process target layers. 
         [0006]    The multilayer resist process is described in, e.g., Reference 1 (Japanese published unexamined patent application No. 2002-093778). The multilayer resist process described in Reference 1 will be summarized. 
         [0007]    First, on a lower layer (silicon oxide-based insulating film) to be processed, a lower resist film (spin-on type carbon film) having etching selectivity with respect to the lower material, an oxide film (SOG film) having etching selectivity with respect to the upper resist film, and a photoresist film are sequentially formed. 
         [0008]    Then, the photoresist film is patterned by photolithography, and with the photoresist film as the mask, the oxide film is etched to transfer a pattern of the photoresist film onto the oxide film. 
         [0009]    Next, with the patterned oxide film as the mask, the lower resist film is etched to transfer the pattern of the oxide film onto the lower resist film. 
         [0010]    Next, with the lower resist film as the mask, the lower layer is processed. 
         [0011]    Reference 2 (Pamphlet of International Patent Application Unexamined Publication No. 00/079586), Reference 3 (Japanese published unexamined patent application No. 2001-110784), Reference 4 (Japanese published unexamined patent application No. 2002-110647), Reference 5 (Japanese published unexamined patent application No. 2002-373937) and Reference 6 (Japanese published unexamined patent application No. 2003-045964) also disclose related arts. 
       SUMMARY OF THE INVENTION 
       [0012]    The inventors of the present application have made earnest studies of the application of above-described multilayer resist process to the dual damascene process. However, it has been found that in the process of the preceding via mode in which via-holes are formed before interconnection trenches are formed, damages are introduced into the lower structures in the process of forming the interconnection trenches. 
         [0013]    An object of the present invention is to provide a method for fabricating a semiconductor device using the multilayer resist process, more specifically a method for fabricating a semiconductor device which can pattern the lower resist film without damaging the lower structure and, by using the lower resist film, can process a downsized pattern with high controllability. 
         [0014]    According to one aspect of the present invention, there is provided a method for fabricating a semiconductor device comprising the steps of: forming over an organic resist film a mask film having etching characteristics different from those of the organic resist film and having an opening formed in a prescribed region; and etching the organic resist film with the mask film as a mask, in the step of etching the organic resist film, the organic resist film being etched with a mixed gas of nitrogen gas and oxygen gas. 
         [0015]    According to another aspect of the present invention, there is provided a method for fabricating a semiconductor device comprising the steps of: forming an insulating film having a first opening in a first region; forming an organic resist film over the insulating film and in the first opening; forming a mask film having etching characteristics different from those of the organic resist film over the organic resist film; forming a second opening in the mask film in a second region including at least a part of the first region; and etching the organic resist film with the mask film as a mask, in the step of etching the organic resist film, the organic resist film being etched with a mixed gas of nitrogen gas and oxygen gas. 
         [0016]    According to the present invention, in the dual damascene process using the preceding via mode using a multilayer resist, N 2 /O 2  or N 2 /O 2 /CF gas is used in etching a lower resist film in forming an interconnection trench, whereby the lower resist film is patterned without damaging the lower structure, and the lower resist film is vertically processed. Accordingly, with the thus formed lower resist film as a mask, the lower structure is etched to thereby process a downsized pattern with good controllability. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0017]      FIGS. 1A-1C ,  2 A- 2 C,  3 A- 3 B,  4 A- 4 B and  5 A- 5 C are sectional views of the semiconductor device in the steps of the method for fabricating the same according to one embodiment of the present invention, which show the method. 
           [0018]      FIGS. 6A and 6B  are pictures of sectional configurations formed by etching the resist film with NH 3  gas. 
           [0019]      FIG. 7  is a graph of the oxygen flow rate ratio dependency of the bowing amount in the etching with N 2 /O 2  gas. 
           [0020]      FIGS. 8A and 8B  are pictures of sectional configurations formed by etching the resist film with an oxygen gas or a mixed gas of oxygen and nitrogen. 
           [0021]      FIGS. 9A and 9B  are sectional configurations of the resist film etched under low chamber internal pressure and under high chamber internal pressure. 
           [0022]      FIGS. 10A-10C  are sectional configurations formed by etching the resist film with N 2 /O 2  gas. 
           [0023]      FIG. 11  is a graph of the oxygen flow rate ratio dependency of the bowing amount in the etching with N 2 /O 2 /C 4 F 6  gas. 
           [0024]      FIG. 12  is a sectional configuration formed by etching the resist film with N 2 /O 2 /C 4 F 6  gas. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    The method for fabricating the semiconductor device according to one embodiment of the present invention will be explained with reference to  FIGS. 1A to 12 . 
         [0026]      FIGS. 1A to 5C  are sectional views of a semiconductor device in the steps of the method for fabricating the same according to the present embodiment, which show the method.  FIGS. 6A and 6B  are pictures of sectional configurations formed by etching the resist film with NH 3  gas.  FIG. 7  is a graph of the oxygen flow rate ratio dependency of the bowing amount in the etching with N 2 /O 2  gas.  FIGS. 8A and 8B  are pictures of sectional configurations formed by etching the resist film with an oxygen gas or a mixed gas of oxygen and nitrogen.  FIGS. 9A and 9B  are sectional configurations of the resist film etched under low chamber internal pressure and under high chamber internal pressure.  FIGS. 10A-10C  are sectional configurations formed by etching the resist film with N 2 /O 2  gas.  FIG. 11  is a graph of the oxygen flow rate ratio dependency of the bowing amount in the etching with N 2 /O 2 /C 4 F 6  gas.  FIG. 12  is a sectional configuration formed by etching the resist film with N 2 /O 2 /C 4 F 6  gas. 
         [0027]    Before the present invention is specifically described, the method for fabricating the semiconductor device the present invention is applied to will be explained with reference to  FIGS. 1A to 5C . 
         [0028]    First, an SiC film  14   a  of, e.g., a 50 nm-thick, an SiOC film  14   b  of, e.g., a 250 nm-thick, an SiC film  14   c  of, e.g., a 30 nm-thick, an SiOC film  14   d  of, e.g., a 200 nm-thick, an SiO film  14   e  of, e.g., a 100 nm-thick and an SiN film  14   f  of, e.g., a 50 nm-thick are sequentially deposited by, e.g., CVD method on an inter-layer insulating film  10  with an interconnection  12  of mainly copper buried in ( FIG. 1A ). An inter-layer insulating film  14  of these films is thus formed. The SiC film  14   a,  the SiC film  14   c  and the SiN film  14   f  are used respectively as a barrier layer, an intermediate stopper layer and a hard mask. The inter-layer insulating film  10  is formed on a semiconductor substrate with devices, such as transistors, etc., formed on. 
         [0029]    Next, on the inter-layer insulating film  14 , a resist film  16   a  of an organic resist material of, e.g., a 500 nm-thick, an SOG film  16   b  of, e.g., a 100 nm-thick, a BARC film  16  of, e.g., a 82 nm-thick and a resist film  16   d  of, e.g., a 300 nm-thick are formed by, e.g., spin coating method. A multilayer resist film  16  of these films is thus formed on the inter-layer insulating film  14 . The resist film  16   a  is the resist film for etching the inter-layer insulating film  14 , the SOG film  16   b  is the hard mask for patterning the resist film  16   a,  and the BARC film  16   c is an organic anti-reflection film, and the resist film  16   d  is, e.g., a photosensitive ArF photoresist. 
         [0030]    Then, the resist film  16   d  is patterned by photolithography to remove the resist film  16   d  in the region for a via-hole to be formed in ( FIG. 1B ). 
         [0031]    Then, with the resist film  16   d  as the mask, the BARC film  16   c and the SOG film  16   b  are anisotropically etched to transfer the pattern of the resist film  16   d  onto the SOG film  16   b  ( FIG. 1C ). The BARC film  16   c  and the resist film  16   b  are anisotropically etched, e.g., by a reactive plasma etching system under a 50 mTorr chamber internal pressure, at a 300 W power, with CF 4  as the etching gas, at a 100 sccm CF 4  flow rate, and for a 60 second etching period of time. 
         [0032]    Then, with the SOG film  16   b  as the mask, the resist film  16   a  is dry etched to remove the resist film  16   a  in the region for a via-hole to be formed in ( FIG. 2A ). The BARC film  16   c  and the resist film  16   d  on the SOG film  16   b  are removed in this etching. The resist film  16   a  is anisotropically etched, e.g., by, a reactive plasma etching system under a 20 mTorr chamber internal pressure, at a 200 W power, with N 2 /H 2  as the etching gas, at a 200/200 sccm N 2 /H 2  flow rate, and for a 200 second etching period of time. 
         [0033]    Then, with the resist film  16   a  as the mask, the SiN film  14   f,  the SiO film  14   e,  the SIOC film  14   d,  the SiC film  14   c  and the SiOC film  14   b  are anisotropically etched to open the via-hole  18  down to the SiC film  14   a  ( FIG. 2B ). The SOG film  16   b  on the resist film  16   a  is removed in this etching. The SiN film  14   f,  the SiO film  14   e,  the SIOC film  14   d,  the SiC film  14   c  and the SIOC film  14   b  are anisotropically etched, e.g., by reactive plasma etching system, under a 35 mTorr chamber internal pressure, at a 1000 W power, with C 5 F 8 /Ar/O 2  as the etching gas, a 10/500/12 sccm C 5 F 8 /Ar/O 2  flow rate, and a 40 second etching period of time. 
         [0034]    Then, the resist film  16   a  is removed by ashing ( FIG. 2C ). The resist film  16   a  is ashed by a plasma ashing system, e.g., under a 10 mTorr chamber internal pressure, at a 300 W power, with O 2  as the ashing gas, at a 300 sccm O 2  flow rate, and a 48 second ashing period of time. 
         [0035]    Next, a resist film  20   a  of an organic resist material of, e.g., a 500 nm-thick is formed by, e.g., spin coating method. The resist film  20   a  is formed, filling the via-hole  18  ( FIG. 3A ). Preferably, the surface of the resist film  20   a  is flat, because films to be formed on the resist film  20   a  can be flat, which permits photolithography to be performed without considering the problem of the depth of focus. 
         [0036]    Then, an SOG film  20   b  of, e.g., a 100 nm-thick, a BARC film  20   c  of, e.g., a 82 nm-thick and a resist film  20   d  of, e.g., a 300 nm-thick are formed on the resist film  20   a  by, e.g., spin coating method. On the SiN film  14   f,  a multilayer resist film  20  of thus formed the resist film  20   a,  the SOG film  20   b,  the BARC film  20   c  and the resist film  20   d  is formed. The resist film  20   a  is the resist film to be used in etching the inter-layer insulating film  14 , the SOC film  20   b  is to be used as the hard mask for patterning the resist film  20   a,  the BARC film  20  is an anti-reflection film, and the resist film  20   d  is, e.g., a photosensitive ArF photoresist. 
         [0037]    Then, the resist film  20   d  is patterned by photolithography to move the resist film  20   d  in the region for an interconnection trench to be formed in ( FIG. 3B ). 
         [0038]    Next, with the resist film  20   d  as the mask, the BARC film  20  and the SOG film  20   b  are anisotropically etched to transfer the pattern of the resist film  20   d  onto the SOG film  20   b  ( FIG. 4A ). The BARC film  20   c  and the SOG film  20   b  are anisotropically etched, e.g., by a reactive plasma etching system, under a 50 mTorr chamber internal pressure, at a 300 W power, with CF 4  as the etching gas, at a 100 sccm CF 4  flow rate, and a 60 second etching period of time. 
         [0039]    Then, with the SOG film  20   b  as the mask, the resist film  20   a  is dry etched to remove the resist film  20   a  in the region for the interconnection trench to be formed in. At this time, the resist film  20   a  is left in the via-hole  18  ( FIG. 4B ). The BARC film  20   c  and the resist film  20   d  on the SOG film  20   b  are removed in this etching. 
         [0040]    The resist film  20   a  is anisotropically etched by, e.g., a reactive plasma etching system, e.g., under a 35 mTorr chamber internal pressure, at a 100 W power, with N 2 /O 2  as the etching gas and at a 290/10 sccm N 2 /O 2  flow rate, or, e.g., under a 40 mTorr chamber internal pressure, at a 150 W power, with N 2 /O 2 /C 4 F 6  as the etching gas and a 250/50/5 sccm N 2 /O 2 /C 4 F 6  flow rate. As will be described later, this etching step mainly characterizes the present invention. 
         [0041]    Then, with the resist film  20   a  as the mask, the SiN film  14   f  and the SiO film  14   e  are anisotropically etched to remove the SiN film  14  and the SiO film  14   e  in the region for an interconnection trench to be formed in. The SiN film  14   f  is anisotropically etched, e.g., by a reactive plasma etching system, under a 40 mTorr chamber internal pressure, at a 200 W power, with CHF 3 /Ar/O 2  as the etching gas, at a 20/200/10 sccm CHF 3 /Ar/O 2  flow rate. The SiO film  14   e  is anisotropically etched, e.g., by a reactive plasma etching system under a 60 mTorr chamber internal pressure, at a 200 W power, with C 4 F 6 /Ar/O 2  as the etching gas and at a 30/400/20 sccm C 4 F 6 /Ar/O 2  flow rate. 
         [0042]    Next, with the resist film  20   a  as the mask and the SiC film  14   c  as the stopper, the SIOC film  14   d  is anisotropically etched to form the interconnection trench  22  in the SIOC film  14   c.  The SOG film  20   b  on the resist film  20   a  is removed by this etching. The SIOC film  14   d  is anisotropically etched, e.g., by a reactive plasma etching system under a 35 mTorr chamber internal pressure, at a 100 W power, with N 2 /O 2  as the etching gas, at a 290/10 sccm N 2 /O 2  flow rate and a 200 second etching period of time. 
         [0043]    Then, the resist film  20   a  is removed by ashing. The resist film  20   a  is ashed by a plasma ashing system, e.g., under a 10 mTorr chamber internal pressure, at a 300 W power, with O 2  as the ashing gas, at a 300 sccm O 2  flow rate and a 48 second ashing period of time. 
         [0044]    Next, the SiC film  14   a  on the bottom of the via-hole  18  is anisotropically etched to open the via-hole  18  down to the interconnection  12  ( FIG. 5A ). The SiC film  14   a  is anisotropically etched, e.g., by a reactive plasma etching system, under a 50 mTorr chamber internal pressure, at a 400 W power, with CH 2 F 2 /Ar/O 2  as the etching gas and at a 20/200/25 sccm CH 2 F 2 /Ar/O 2  flow rate. 
         [0045]    Then, a barrier metal and a Cu seed are deposited by sputtering, and then Cu plating is performed. Thus, the via-hole  18  and the interconnection trench  22  are filled with a barrier metal  24  and a Cu film  26  ( FIG. 5B ). 
         [0046]    Next, the Cu film  26  and the barrier metal  24  are polished by CMP method to leave the Cu film  26  and the barrier metal  24  selectively in the via-hole  18  and the interconnection trench  22 . Thus, an interconnection  28  formed of the barrier metal  24  and the Cu film  26  and connected to the interconnection  12  is formed in the via-hole  18  and the interconnection trench  22  ( FIG. 5C ). 
         [0047]    Hereafter, as required, interconnection layers are repeatedly formed on the interconnection  28  to fabricate a semiconductor device having the multi-level interconnections. 
         [0048]    The present invention is characterized mainly in that in the above-described method for fabricating the semiconductor device, N 2 /O 2  gas or N 2 /O 2 /CF gas is used as the etching gas for etching the resist film  20   a  in the step illustrated in  FIG. 4B . 
         [0049]    Conventionally, NH 3  and N 2 /H 2  have been predominantly used in etching organic resist films used as the mask for etching inter-layer insulating films. However, the earnest studies of the inventors of the present application have found that in the above-described method for fabricating the semiconductor device, etching the resist film  20   a  with NH 3  or N 2 /H 2  in the step of  FIG. 4B  generates cracks down to the inter-layer insulating film  10 . 
         [0050]      FIGS. 6A-6C  are pictures of sectional configurations formed by etching the resist film  20   a  with NH 3  as the etching gas, which were taken by a scanning electron microscope.  FIG. 6A  is the sectional configuration immediately after the resist film  20   a  has been etched.  FIG. 6B  is the sectional configuration immediately after the SiN film  14   f  and the SiO film  14   e  have been etched.  FIG. 6C  is the sectional configuration immediately after the interconnection trench  22  has been formed and before the ashing. 
         [0051]    As seen in  FIG. 6A , immediately after the resist film  20   a  has been etched, a crack (circled in the drawing) is observed between the resist film  20   a  and the side wall of the via-hole  18 . The crack is increased after the SiN film  14   f  and the SiO film  14   e  have been etched (see  FIG. 6B ). Then, after the interconnection trench  22  has been formed, the crack is further increased down to even the inter-layer insulating film  10  with the interconnection layer  12  buried in ( FIG. 6C ). There is the risk that such crack will much affect the reliability of the semiconductor device, and the generation of the crack must be prevented. 
         [0052]    The mechanism that the crack is generated between the resist film  20   a  and the side wall of the via-hole  18  is not clear, but the etching gas of NH 3  and N 2 /H 2  will make some action to the interface between the resist film  20   a  and the side wall of the via-hole  18  to thereby lower the adhesion therebetween. 
         [0053]    In such background, the inventors of the present application have made earnest studies of the etching conditions for the resist film  20   a  to be the first to find that N 2 /O 2  or N 2 /O 2 /CF is used as the etching gas, and the chamber internal pressure and the etching gas flow rate are suitably controlled, whereby the generation of cracks between the resist film  20   a  and the side wall of the via-hole  18  can be prevented, and the resist film  20   a  can be etched in a good vertical processed configuration. 
         [0054]    The etching conditions the inventors of the present application have found will be detailed below. 
         [0055]    In the multilayer resist process, generally a lower resist film is processed by using oxygen gas only. In etching a lower resist film by using oxygen gas, the horizontal etching also tends to go on, and the resist film is processed in a bowing configuration. Such bowing configuration does not matter when a pattern size of a semiconductor device is relatively large. However, in processing a fine pattern, such bowing configuration is a problem, such bowing configuration is an obstacle to accurate processing of the fine pattern. 
         [0056]    Then, the inventors of the present application studied whether the etching with oxygen gas can be applied to the etching of the resist film  20   a  in the above-described method for fabricating the semiconductor device and additionally means for preventing the bowing configuration. Resultantly, N 2 /O 2  or N 2 /O 2 /CF gas was used as the etching gas, and the chamber internal pressure and the etching gas flow rate were suitably controlled, whereby the resist film  20   a  could be etched into a good vertical processed configuration, and the generation of cracks between the resist film  20   a  and the side wall of the via-hole  18  could be prevented. 
         [0057]      FIG. 7  is a graph of the oxygen flow rate ratio dependency of the bowing amount of the etching with N 2 /O 2  gas. The bowing amounts are taken on the vertical axis, and the bowing amounts were determined by B-A in which A indicates an opening width of the mask, and B indicates a maximum width of an opening formed in the resist film  20   a  by using the mask. Flow rate ratios (%) of oxygen gas to a total gas flow rate are taken on the horizontal axis. The flow rate ratios of the oxygen gas were adjusted by diluting the oxygen gas with nitrogen gas. The other etching conditions were a 35 mTorr chamber internal pressure, a 100 W power and a 300 sccm total flow rate of N 2  and O 2 , which were fixed. 
         [0058]    As shown, the bowing amount is decreased by lowering the flow rate ratio of the oxygen gas. When the flow rate ratio of the oxygen gas is below 10%, the bowing amount is drastically decreased to about 5 nm at 5% and to about 2 nm at 1-3%. A gas to be mixed with the oxygen gas is preferably nitrogen. Mixing, e.g., argon in place of nitrogen cannot suppress the bowing. Although the mechanism for this is not clear, the nitrogen will be acting to protect the side wall of the processed part. 
         [0059]      FIG. 8A  is a picture of the sectional configuration formed by etching the resist film  20   a  with oxygen gas only, which was taken by a scanning electron microscope. The etching conditions were a 80 mTorr chamber internal pressure, a 100 W power and a 250 sccm O 2  flow rate. As shown, the resist film  20   a  is bowed unsuitably for the downsizing. 
         [0060]      FIG. 8B  is a picture of the sectional configuration formed by etching the resist film  20   a  with a mixed gas of oxygen and nitrogen, which was taken by a scanning electron microscope. The etching conditions were a 35 mTorr chamber internal pressure, a 100 W power and a 290/10 sccm N 2 /O 2  flow rate(oxygen flow rate ratio: 3.3%). As shown, the resist film  20   a  was processed vertically without bowing configuration. No crack is generated between the resist film  20   a  and the via-hole  18 . 
         [0061]    The processed configuration of the resist film  20   a  is changed depending on the chamber internal pressure. 
         [0062]      FIG. 9A  is a picture of the sectional configuration formed by etching the resist film  20   a  with a mixed gas of oxygen and nitrogen under low pressure, which was taken by a scanning electron microscope. The etching conditions other than a 15 mTorr chamber internal pressure were the same as the case of  FIG. 8B . As shown, even with the etching gas with nitrogen added to, under a low chamber internal pressure of 15 mTorr, the so-called sub-trench configuration, which has a groove formed on the bottom peripheral part of a trench and a hole deeper than the bottom center thereof, is formed, which affects the later etching. 
         [0063]      FIG. 9B  is a picture of the sectional configuration formed by etching the resist film  20   a  under high pressure and with a mixed gas of oxygen and nitrogen, which was taken by a scanning electron microscope. The etching conditions other than a 150 mTorr chamber internal pressure were the same as the case of  FIG. 8B . As shown, with the chamber internal pressure as high as 150 mTorr, the resist film  20   a  is bowed unsuitably for the downsizing. 
         [0064]    When N 2 /O 2  is used as the etchant for the resist film  20   a,  the flow rate ratio of the oxygen gas is less than 10%, preferably not more than 5%, more preferably 1-3%. The upper limit value of the flow rate ratio of the oxygen gas can be suitably set in accordance with an allowable bowing amount. The etching rate is lowered by lowing the flow rate ratio of the oxygen gas, and the lower limit value of the flow rate ratio of the oxygen gas can be suitably set in accordance with a prescribed etching rate. 
         [0065]    It is preferable to set the chamber internal pressure at 25-50 mTorr, more preferably, at 30-40 mTorr. This is because under a pressure less than 25 mTorr, the etching rate of the resist film  20   a  is extremely low, and often the sub-trench configuration shown in  FIG. 9A  is formed. On the other hand, under a pressure of above 50 mTorr, the effect of adding oxygen is enhanced, and the bowing configuration shown in  FIG. 9B  tends to be formed. 
         [0066]      FIGS. 10A-10C  are pictures of sectional configurations formed by etching the resist film  20   a  with N 2 /O 2  gas, which were taken by a scanning electron microscope.  FIG. 10A  is the sectional configuration immediately after the resist film  20   a  has been etched.  FIG. 10B  is the sectional configuration immediately after the SiN film  14   f  and the SiO film  14   e  have been etched.  FIG. 10C  is the sectional configuration after the interconnection trench  22  has been formed, and ashing has been performed. 
         [0067]    As seen in  FIG. 10A , immediately after the resist film  20   a  has been etched, no crack is generated between the resist film  20   a  and the side wall of the via-hole  18 . The processed configuration of the resist film  20   a  is vertical. No crack is generated after the SiN film  14   f  and the SiO film  14   e  have been etched ( FIG. 10B ) and after the interconnection trench has been formed ( FIG. 10C ). 
         [0068]    As the etching gas for the resist film  20   a,  N 2 /O 2 /CF gas other than N 2 /O 2  gas can be used. CF gas (fluorocarbon gas), which forms a protection film on the side wall of an etched part, is expected to prevent the bowing. The use of CF gas can enlarge the process window for etching the resist film  20   a.  As the CF gas can be used C x F y  or CH a F b  used in the usual semiconductor process, more specifically, C 3 F 6 , C 4 F 8 , C 4 F 6 , C 5 F 8 , CH 2 F 2 , CHF 3 , CH 3 F or others. 
         [0069]      FIG. 11  is a graph of the oxygen flow rate ratio dependency of the bowing amount of the etching with N 2 /O 2 /C 4 F 6  gas. The bowing amounts are taken on the vertical axis, and the bowing amounts were determined by B-A in which A indicates an opening width of the mask, and B indicates a maximum width of an opening formed in the resist film  20   a  by using the mask. Flow rate ratios of oxygen gas (%) to a total gas flow rate are taken on the horizontal axis. The flow rate ratio of the oxygen gas is adjusted by the flow rate of the nitrogen gas. The specific etching conditions are a 35 mTorr chamber internal pressure, a 100 W power, a 60 sccm flow rate of C 4 F 6  as the CF gas, a 300 sccm total flow rate of the N 2 , O 2  and C 4 F 6 , which were fixed. 
         [0070]    As shown, the bowing amount is decreased by lowering the flow rate ratio of the oxygen gas. When the flow rate ratio of the oxygen is below 12%, the bowing amount is drastically decreased to about 6 nm at 7% and to about 1 nm at 3-5%. 
         [0071]      FIG. 12  is a picture of the sectional configuration of the resist film  20   a  etched with N 2 /O 2 /C 4 F 6 , which was taken by a scanning electron microscope. The etching conditions were a 35 mTorr chamber internal pressure, a 100 W power and a 250/5/50 sccm of N 2 /O 2 /C 4 F 6 flow rate (oxygen flow rate ratio: about 1.6%). As shown, the processed configuration of the resist film  20   a  is vertical, and no bowing configuration is generated. No crack is generated even between the resist film  20   a  and the via-hole  18 . 
         [0072]    When N 2 /O 2 /CF is used as the etching gas for the resist film  20   a,  the flow rate ratio of the oxygen gas is less than 12%, preferably not more than 7%, more preferably not more than 5%. The upper limit value of the flow rate ratio of the oxygen gas is suitably set in accordance with an allowed bowing amount. The etching rate is lowered by lowering the flow rate ratio of the oxygen gas, and the lower limit value of the flow rate ratio of the oxygen gas can be suitably set in accordance with a required etching rate. 
         [0073]    It is preferable to set the flow rate ratio of the CF gas at 15-25%. This is because when the flow rate ratio of the CF gas is less than 15%, the effect of forming the protection film is insufficient, and when the flow rate ratio of the CF gas is more than 25%, an organic resist film used as the mask (SOG film  20   b ) is etched. 
         [0074]    Thus, when the resist film  20   a  is etched with N 2 /O 2  as the etching gas, the flow rate ratio of the oxygen gas is set at less than 10%, preferably not more than 5%, more preferably 1-3%. The chamber internal pressure is set at 25-50 mTorr, more preferably 30-40 mTorr. When N 2 /O 2 /CF is used as the etching gas, the flow rate ratio of the oxygen gas is set at less than 12%, preferably not more than 7%, more preferably not more than 5%. The flow rate ratio of the CF gas is set at 15-25%. Thus, the generation of cracks between the resist film  20   a  and the side wall of the via-hole  18  can be prevented, and the resist film  20   a  can be etched in good vertical processed configuration. 
         [0075]    As described above, according to the present embodiment, in the dual damascene process of the preceding via mode using a multilayer resist, N 2 /O 2  gas or N 2 /O 2 /CF gas is used in etching a lower resist film for forming an interconnection trench, whereby the generation of cracks between the lower resist film buried in a via-hole and the inter-layer insulating film can be prevented. The processed configuration of the lower resist film can be made vertical. 
       Modified Embodiments  
       [0076]    The present invention is not limited to the above-described embodiment and can cover other various modifications. 
         [0077]    For example, in the above-described embodiment, the present invention is applied to the steps of forming the interconnection trench in the dual damascene process of the preceding via mode using a multilayer resist, but may be applied to other steps. For example, the present invention may be applied to the step of forming the via-hole  18  shown in  FIG. 2A . The etching method of the present invention is used to thereby vertically process the resist film  16   a  suitably for forming fine patterns. 
         [0078]    In the above-described embodiment, the interconnection is buried in the inter-layer insulating film of SiN/SiO/SiOC/SiC/SiOC/SiC structure by the dual damascene, but the materials forming the inter-layer insulating film and the layer structure thereof are not limited to the above.

Technology Category: h