Patent Document

BACKGROUND 
     The present invention relates generally to semiconductor device manufacturing techniques and, more particularly, to the use of alignment marks to facilitate the three-dimensional integration of integrated circuit (IC) devices. 
     The packaging density in the electronics industry continuously increases in order to accommodate more electronic devices into a package. In this regard, three-dimensional (3D) wafer-to-wafer stacking technology substantially contributes to the device integration process. Typically, a semiconductor wafer includes several layers of integrated circuitry (e.g., processors, programmable devices, memory devices, etc.) built on a semiconductor substrate. In order to form a 3D wafer stack, two or more wafer substrates are placed on top of one other and bonded. A top layer of the bonded wafer stack may be connected to a bottom layer of the wafer stack utilizing through silicon interconnects or vias. 
     3D wafer stacking technology offers a number of potential benefits, including, for example, improved form factors, lower costs, enhanced performance, and greater integration through system-on-chip (SOC) solutions. In addition, the 3D wafer stacking technology may provide other functionality to the chip. For instance, after being formed, the 3D wafer stack may be diced into stacked dies or chips, with each stacked chip having multiple tiers (i.e., layers) of integrated circuitry. SOC architectures formed by 3D wafer stacking can enable high bandwidth connectivity of products such as, for example, logic circuitry and dynamic random access memory (DRAM), that otherwise have incompatible process flows. At present, there are many applications for 3D wafer stacking technology, including high performance processing devices, video and graphics processors, high density and high bandwidth memory chips, and other SOC solutions. 
     When creating wafer substrates to form a 3D stack, additional processing may be required on the backside plane of the wafer substrate, either prior to or after the completion of the bonding process. Since the backside plane is initially without any features, it effectively is a virgin silicon surface. Alignment of features formed on the unpatterned backside plane to features on the front side of the wafer substrate is critical to functionality of 3D interconnected structures, particularly when utilizing a via-last integration scheme that requires accurate alignment to form interconnections to existing features that are not visible after face-to-face substrate bonding. Present alignment methodologies known in the art used to enable backside first-level alignment require specialized hardware, additional processing, and add micron-scale variability and alignment inaccuracy to the manufacturing process. To enable high-density 3D structures, improved accuracy and cost-effective alignment processes are required. 
     BRIEF SUMMARY 
     The various advantages and purposes of the exemplary embodiments as described above and hereafter are achieved by providing, according to a first aspect of the exemplary embodiments, a method of forming alignment marks to enable three dimensional (3D) structures. The method includes forming apertures in a first surface of a first semiconductor substrate; optionally filling the apertures; bonding the first surface of the first semiconductor substrate to a first surface of a second semiconductor substrate; thinning the first semiconductor substrate on a second surface of the first semiconductor substrate to a level to provide optical contrast between the apertures and the first semiconductor substrate; and aligning a feature on the second surface of the first semiconductor substrate using the apertures as at least one reference alignment mark. 
     According to a second aspect of the exemplary embodiments, there is provided a method of forming alignment marks to enable three dimensional (3D) structures. The method includes obtaining a first semiconductor substrate and a second semiconductor substrate; forming apertures in a first surface of the first semiconductor substrate; optionally filling the paertues; bonding the first surface of the first semiconductor substrate to a first surface of the second semiconductor substrate; thinning the first semiconductor substrate on a second surface of the first semiconductor substrate to a level to provide optical contrast between the apertures and the first semiconductor substrate; and aligning a feature on the second surface of the first semiconductor substrate using the apertures as at least one reference alignment mark. 
     According to a third aspect of the exemplary embodiments, there is provided a semiconductor structure which includes a semiconductor substrate having an alignment mark on a first surface of the semiconductor substrate that continues through the semiconductor substrate to a second surface of the semiconductor substrate. 
     According to a fourth aspect of the exemplary embodiments, there is provided a semiconductor structure which includes a first semiconductor substrate having a first and a second surface, the first semiconductor substrate having apertures extending from the first surface to the second surface; a second semiconductor substrate having a first surface, wherein the first surface of the first semiconductor substrate is bonded to the first surface of the second semiconductor substrate; and a feature formed on the second surface of the first semiconductor substrate using the apertures in the second surface as a reference alignment mark for the printed feature. The apertures may optionally be partially or completely filled with a material. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
       The features of the exemplary embodiments believed to be novel and the elements characteristic of the exemplary embodiments are set forth with particularity in the appended claims. The Figures are for illustration purposes only and are not drawn to scale. The exemplary embodiments, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which: 
         FIGS. 1 to 5  illustrate the steps in the three dimensional stacking of semiconductor wafers wherein: 
         FIG. 1  is a cross sectional view of prepared top and bottom semiconductor substrates prior to bonding; 
         FIG. 2  is a cross sectional view of the top and bottom semiconductor substrates of  FIG. 1  bonded together; 
         FIG. 3  is a cross sectional view illustrating the thinning of the top semiconductor substrate to expose an exemplary embodiment of the alignment marks; 
         FIG. 4  is a cross sectional view illustrating the formation of a circuit feature utilizing the alignment marks; and 
         FIG. 5  is a cross sectional view of an additional semiconductor substrate bonded to the top semiconductor substrate utilizing the alignment marks. 
         FIG. 6  are planar views of the alignment marks and a printed alignment feature. 
         FIG. 7  is an exemplary embodiment for forming filled apertures which become the alignment marks. 
         FIG. 8  is another exemplary embodiment for forming filled apertures which become the alignment marks. 
         FIG. 9  is another exemplary embodiment for forming filled apertures which become the alignment marks. 
         FIG. 10  is another exemplary embodiment for forming filled apertures which become the alignment marks. 
         FIG. 11  is another exemplary embodiment for forming filled apertures which become the alignment marks. 
         FIG. 12  is another exemplary embodiment for forming unfilled apertures which become the alignment marks. 
     
    
    
     DETAILED DESCRIPTION 
     Alignment marks are critical to the manufacturing of 3D semiconductor substrates. Alignment marks are needed on the front side of the semiconductor substrates to align the semiconductor substrates prior to bonding into a 3D stack. Alignment marks are also needed on the backside of the semiconductor substrates to add features to the back side of the semiconductor substrate, to add through silicon vias after the semiconductor substrates are bonded and to join additional semiconductor substrates to the 3D stack. Transferring alignment marks from the front side of the semiconductor substrate to the back side is possible using current methodologies known in the art, but the transfer of alignment marks needs to be done prior to substrate bonding, requires specialized tooling and several additional costly process steps, and result in decreased alignment accuracy compared to conventional UV photolithography methods known in the art. 
     The present invention proposes alignment marks and a process for forming the alignment marks which is less complicated and more accurate than methods currently practiced in the art.  FIGS. 1 to 5  illustrate a process for forming alignment marks which are created on the front side of the semiconductor substrate but are functional to enable alignment with respect to the back side of the semiconductor substrate. 
     Referring now to  FIG. 1 , there is illustrated a bottom semiconductor substrate  102  and a top semiconductor substrate  104 . While bottom semiconductor substrate  102  and top semiconductor substrate  104  will be described with respect to certain features on the semiconductor substrates  102 ,  104 , it should be understood that the present invention is useful for the stacking and bonding of any type of semiconductor substrate having any kind of features. In an exemplary embodiment, bottom semiconductor substrate  102  has a semiconductor base substrate  106  which may be made from any semiconductor material. The semiconductor base substrate  106  may include any type of semiconductor device as well as wiring and contact levels required to create functional integrated circuits. For clarity, any such semiconductor devices and associated wiring are omitted. On top of semiconductor base substrate  106  may be a dielectric layer  108  followed by another dielectric layer  110 . Dielectric layers  108  and  110  may be oxide or any other dielectric material known in the art including but not limited to nitride, oxynitride and organic dielectrics. 
     Within dielectric layer  110  are landing pad structures  112  composed of a conductive material, which may connect to the semiconductor devices within semiconductor base substrate  106 . In a preferred embodiment, dielectric layer  108 , landing pad structure  112  and other wiring layers not shown are located in the back end of the line (BEOL) wiring layers which may include, for example, active and passive elements or devices. In other embodiments, dielectric layer  108  and landing pad structure  112  may be incorporated in other levels of the semiconductor device, such as a contact level. Landing pad structure  112  may be a standard existing wire structure rather than an independent feature incorporated in a wiring layer. One purpose of landing pads  112  may be to connect with through silicon vias in a subsequent process. The landing pads  112  may be composed of a metal, for example copper, aluminum, tungsten, or gold, and may contact wiring levels above and below the landing pads  112 . Lastly, bottom semiconductor substrate  102  may include a bonding layer  114  for bonding semiconductor substrate  102  with semiconductor substrate  104 . Bonding layer  114  may include, for example, an activated oxide layer. Other types of materials for bonding layer  114  may be possible, and the scope of the present invention is not limited to any specific substrate bonding methodology or bonding material. 
     In an exemplary embodiment, top semiconductor substrate  104  has a semiconductor base substrate  116  which may be made from any semiconductor material. The semiconductor base substrate  116  may include any type of semiconductor device as well as wiring and contact levels required to create functional integrated circuits. For clarity, any such semiconductor devices and associated wiring are omitted. In addition, semiconductor substrate  116  may be a different type of semiconductor substrate than semiconductor substrate  106  and also may contain different kinds of semiconductor devices. On top of semiconductor base substrate  116  may be a dielectric layer  118  followed by another dielectric layer  120 . Dielectric layers  118  and  120  may be oxide or any other dielectric material known in the art including but not limited to nitride, oxynitride and organic dielectrics. 
     Within dielectric layer  120  may be landing pad structure  122  composed of a conductive material, which may connect to the semiconductor devices within semiconductor base substrate  116 . In a preferred embodiment, dielectric layer  118 , dielectric layer  120 , landing pad structure  122  and other wiring layers not shown are located in the back end of the line (BEOL) wiring layers which may include, for example, active and passive elements or devices. In other embodiments, dielectric layers  118 ,  120 , and landing pad structure  122  may be incorporated in other levels of the semiconductor device, such as a contact level. Landing pad structure  122  may be a standard existing wire structure rather than an independent feature incorporated in a wiring layer. One purpose of landing pads  122  may be to connect with through silicon vias in a subsequent process. The landing pads  122  may be composed of a metal, for example, copper, aluminum, tungsten, or gold, and may contact wiring levels above and below the landing pads  122 . Top semiconductor substrate  104  may include a bonding layer  124  as explained above for bonding semiconductor substrate  104  with semiconductor substrate  102 . 
     Additional alignment marks can be included in respective bonding layers  114  and  124  or other locations within the structures of substrates  102  and  104  to enable visual alignment of exposed surfaces during bonding as required. Any such alignment marks have been omitted from the Figures since such alignment marks are not relevant to the scope of the present invention, 
     In addition, top semiconductor substrate  104  includes filled apertures  126  which may perform the function of reference alignment marks as will be explained hereafter. The filled apertures  126  may be partially filled or entirely filled. The filled apertures  126  are blind vias or blind trenches which extend only partly into semiconductor base substrate  116 . The materials for the filled apertures  126  are chosen so as to provide good optical contrast between the filled apertures  126  and the surrounding semiconductor substrate  104 . The filled apertures  126  may be accurately placed and formed with respect to a front surface  128  of the semiconductor substrate  104  using standard semiconductor patterning methodologies known in the art. The depth, size, and geometry of filled apertures  126  is dependent on the manufacturing processes and integration selected, and are not limited by the scope of the present invention. 
     In a subsequent process, top semiconductor substrate  104  will be thinned to enable good optical contrast between semiconductor substrate  104  and the filled apertures  126  on a back surface  130  of the semiconductor substrate  104 . The front surface  128  is opposite the back surface  130 . Thus, once exposed to a thickness of the top semiconductor substrate  104  after thinning that enables sufficient optical contrast, the filled apertures  126  may be used as reference alignment marks for features printed or added to the back surface  130  of the semiconductor substrate  104  using standard photolithography and patterning methodologies known in the art to enable first-level patterning on the unpatterned surface  130  with a high degree of accuracy with respect to features within substrate  104  that are not visible after bonding of substrates  102  and  104 . The accurate placement of the filled apertures  126  with respect to the front surface  128  of the semiconductor substrate  104  will result in equally accurate placement of the filled apertures with respect to the back surface  130  of the semiconductor substrate  104 . 
     The process for forming the filled apertures  126  will be discussed subsequently with respect to  FIGS. 7 to 10 . 
     Referring now to  FIG. 2 , top semiconductor substrate  104  has been flipped over and bonded to bottom semiconductor substrate  102 . The bonding methodology utilized may be, for example, oxide-to-oxide bonding such as by annealing. Other forms of bonding, such as adhesive bonding or metal-metal bonding may also be practiced. The scope of the present invention is not limited to any specific substrate bonding methodology or bonding material. 
     Referring now to  FIG. 3 , top semiconductor substrate  104  is then thinned by a conventional process. An exemplary process for thinning top semiconductor substrate  104  may include grinding followed by a dry etch, such as reactive ion etching. Sufficient material must be removed from surface  130  of substrate  104  to enable optical contrast between the filled apertures  126  and substrate  104 . The thickness of substrate  104  required to be removed during thinning is dependent on the depth of filled apertures  126 , the material used to fill filled apertures  126 , and the capability of photolithography equipment to be used for additional first-level alignment on back surface  130 , and the thickness of material removed or remaining is not limited by the scope of this invention. As a result of thinning top semiconductor substrate  104 , filled apertures  126  may then be exposed on the back surface  130  of the top semiconductor substrate  104 . The filled apertures  126  may be flush with the back side surface  130 , may even extend above back surface  130 , or may remain concealed under a thin layer of substrate  104  in the range of 200 to 5000 angstroms if sufficient optical contrast can be attained to enable the reference alignment marks to be functional. 
     Referring now to  FIGS. 6A to 6D , several different exemplary embodiments of the filled apertures  126  are shown. The filled apertures  126 A to  126 D shown in  FIGS. 6A to 6D  are shown as they would appear on the back surface  130  of the top semiconductor substrate  104 . In  FIG. 6A , the filled apertures  126 A may be in the form of a box in a box. In  FIG. 6B , the filled apertures  126 B may be in the form of a circle in a circle. In  FIG. 6C , the filled apertures  126 C may be in the form of lines in lines while in  FIG. 6D , the filled apertures  126 D may be in the form of “L” brackets. Other exemplary embodiments of the filled apertures  126  are within the scope of the present invention. Vias or trenches may be used to form the filled apertures  126 A to  126 D. Dimensions of the filled apertures vary depending on the depth required of the reference alignment mark, and the dimensions of the claimed structures are not limited by the scope of the present invention. 
     The filled apertures  126 A to  126 D may be used as alignment marks in and of themselves. In an exemplary embodiment, an alignment feature may be printed or formed on the back surface  130  of the top semiconductor substrate  104  using the filled apertures  126  as reference points. Thus,  FIG. 6A  has a printed box alignment feature  132 A,  FIG. 6B  has a printed circle alignment feature  132 B,  FIG. 6C  has a printed line alignment feature  132 C and  FIG. 6D  has a printed cross alignment feature. 
     Again, the filled apertures  126 A to  126 D are very accurately located so that the printed alignment features  132 A to  132 D will also be very accurately located. 
     Returning to  FIG. 3 , the filled apertures  126  or printed alignment feature  132  shown in  FIG. 6  may be used to accurately place and create additional circuit features such as through silicon via  134  and through silicon via  136  (assuming that semiconductor base substrate  116  comprises silicon). There may be other circuit features not shown. Through silicon via  134  extends from the back surface  130  of the top semiconductor substrate  104  to landing pad  112  on bottom semiconductor substrate  102  while through silicon via  136  extends from the back surface  130  of the top semiconductor substrate  104  to landing pad  122  on the top semiconductor substrate  104 . Through silicon vias  134 ,  136  may be conventionally formed by etching through the semiconductor base substrate  116  and any intermediate dielectric layers to form apertures and then filling the apertures with an optional liner and a conductive material according to processes known in the art. Through silicon vias  134 ,  136  are shown as being filled with a conductive material. The exemplary embodiments may have applicability to other semiconductor materials in which there will be through vias equivalent to the through silicon vias. Other through silicon via interconnect structures that directly connect substrates  102  and  104  in a single via formation step may also be utilized. The through silicon via integration, methodologies for formation, and materials are not limited by the scope of the present invention. 
     Referring now to  FIG. 4 , in one exemplary embodiment, at least one additional layer of dielectric material  138  may be deposited on the back surface  130  of top semiconductor surface  104 , patterned and then a conductive pad or wiring layer  140  conventionally formed to connect through silicon vias  134 ,  136 . Reference alignment marks  126  may still be functional after additional dielectric layer formation. Further layers and bonding pads may be added to complete the fabrication of the 3D stack of semiconductor substrates followed by dicing to form 3D stacks of individual semiconductor chips. 
     The filled apertures  126  and/or printed features  132  (shown in  FIG. 6 ) in top semiconductor substrate  104  may be used to align with another semiconductor substrate  140  to continue with 3D stacking as shown in  FIG. 5 . Semiconductor substrate  140  may also have filled apertures  142  for printing of features on or adding circuit features to the back surface  143  of semiconductor substrate  140 . In addition, filled apertures  142  may also be advantageous in adding yet another semiconductor substrate (not shown) to the 3D stack of semiconductor substrates. 
     Referring now to  FIGS. 7 to 11 , several different exemplary embodiments are shown for forming the filled apertures  126 . Referring first to  FIG. 7 , in  FIG. 7A  apertures  702  (vias or trenches) are conventionally etched in top semiconductor substrate  104  followed, in  FIG. 7B , by depositing an optional liner  704 , for example of chemical vapor deposited (CVD) titanium nitride, followed by a thin conformal layer  706  of a material that is known to provide sufficient optical contrast with the substrate material to enable use of traditional photolithography methodologies. Layer  706  may consist of conductive material, such as tungsten as a preferred embodiment which provides excellent optical contrast with the substrate material, for example. The aperture  702  is now partially filled. The layer  706  should not entirely fill the filled aperture  702  but leave a hollow space  710 . The thin conformal layer  706  may be, for example, 500 to 1000 angstroms thick. Any overburden of layer  706  is removed using processes known in the art, such as by an anisotropic etch as shown in  FIG. 7C  or by chemical mechanical polishing (CMP). Next, a dielectric layer  708  (such as dielectric layer  120  in  FIG. 1 ) is deposited over the top semiconductor substrate  104  to pinch off the aperture  702 . The top semiconductor substrate  104  is then flipped over, bonded to semiconductor substrate  102  and then thinned as described previously. As a result of the thinning, the bottom  712  of filled aperture  702  now has sufficient optical contrast from substrate  104  to be visible to photolithography equipment as described previously. As shown in  FIG. 7E , the bottom  712  of filled aperture  702  extends above the top semiconductor substrate  104  but bottom  712  of filled aperture  702  may also be flush with top semiconductor substrate  104 , or remain covered by a thin layer of substrate  104  in the range of 200 to 5000 angstroms.  FIG. 11  is an example of where a thin layer  1102  of semiconductor substrate  104  covers the bottom  712  of filled aperture  702 . The thin layer  1102  (in the range of 200 to 5000 angstroms) is thin enough so that there is optical contrast between the filled aperture  702  and semiconductor substrate  104 . During the thinning process, the liner layer  704  may be removed to expose the conformal layer  706 . 
     Another exemplary embodiment of a filled aperture is shown in  FIGS. 8A to 8E . In  FIG. 8A , a bottle shaped trench is conventionally formed in top semiconductor substrate  104 . Thereafter, as shown in  FIG. 8B , an optional liner  804 , for example CVD titanium nitride, is deposited followed by a conformal layer  806  of a material that is known to provide sufficient optical contrast with the substrate material to enable use of traditional photolithography methodologies. Layer  806  may consist of conductive material, such as CVD tungsten as a preferred embodiment which provides excellent optical contrast with the substrate material, for example. Layer  806  pinches off the top of the bottle. The aperture  802  is now partially filled. The conformal layer  806  should not entirely fill the filled aperture  802  but leave a hollow space  810 . Any overburden of the conformal layer  806  may be removed by a chemical mechanical polishing (CMP) process to result in the structure shown in  FIG. 8C . In an optional exemplary embodiment shown in  FIG. 8D , there may be a conformal dielectric layer  814  deposited prior to deposition of the conformal titanium nitride liner  804  and the conformal layer  806 . The top semiconductor substrate  104  is then flipped over, bonded to the bottom semiconductor substrate  102  and then thinned as described previously. As a result of the thinning, the bottom  812  of filled aperture  802  has sufficient optical contrast from substrate  104  to be visible to photolithography equipment as described previously. As shown in  FIG. 8E , the bottom  812  of filled aperture  802  extends above the top semiconductor substrate  104  but bottom  812  of filled aperture  802  may also be flush with top semiconductor substrate  104  or remain covered by a thin layer of semiconductor substrate  104  as shown, for example, in  FIG. 11 . During the thinning process, the liner layer  804  or conformal dielectric layer  814  may be removed to expose the conformal layer  806 . 
     Referring now to  FIGS. 9A to 9E , an aperture  902  (via or trench) is etched in top semiconductor substrate  104  followed by deposition of an optional liner  904 , for example CVD titanium nitride, followed by deposition of a conformal layer  906  of a material that is known to provide sufficient optical contrast with the substrate material to enable use of traditional photolithography methodologies as shown in  FIG. 9A . Layer  906  may consist of conductive material, such as CVD tungsten as a preferred embodiment which provides excellent optical contrast with the substrate material, for example. In  FIG. 9B , a second low-stress nonconformal layer  908  of, for example, tungsten is deposited to pinch off the aperture  902  prior to entirely filling it. Nonconformal deposition of tungsten may be obtained by processing in a diffusion-controlled CVD regime. The aperture  902  is now partially filled. The conformal layers  906 ,  908  should not entirely fill the filled aperture  902  but leave a hollow space  910 . Any overburden of the conformal layers  906 ,  908  may be removed by a CMP process to result in the structure shown in  FIG. 9C . In an optional exemplary embodiment shown in  FIG. 9D , there may be a conformal dielectric layer  914  deposited prior to deposition of the conformal titanium nitride liner  904  and conformal layer  906 . The top semiconductor substrate  104  is then flipped over, bonded to the bottom semiconductor substrate  102  and then thinned as described previously. As a result of the thinning, the bottom  912  of filled aperture  902  has sufficient optical contrast from substrate  104  to be visible to photolithography equipment as described previously. As shown in  FIG. 9E , the bottom  912  of filled aperture  902  extends above the top semiconductor substrate  104  but bottom  912  of filled aperture  902  may also be flush with top semiconductor substrate  104  or remain covered by a thin layer of semiconductor substrate  104  as shown, for example, in  FIG. 11 . During the thinning process, the liner layer  904  or conformal dielectric layer  914  may be removed to expose the conformal layer  906 . 
     Next exemplary embodiments are shown in  FIGS. 10A to 10E . Referring first to  FIG. 10A , an aperture  1002  (via or trench) is etched in top semiconductor substrate  104  followed by deposition of an optional liner  1004 , for example CVD titanium nitride, followed by deposition of a conformal layer  1006  of a material that is known to provide sufficient optical contrast with the substrate material to enable use of traditional photolithography methodologies. Layer  1006  may consist of conductive material, such as CVD tungsten as a preferred embodiment which provides excellent optical contrast with the substrate material, for example. In  FIG. 10B , aperture  1002  is completely filled with a dielectric such as an oxide or nitride  1008 . The aperture  1002  is now completely filled. Any overburden of the conformal layer  1006  and dielectric  1008  may be removed by a CMP process to result in the structure shown in FIG.  10 C. In an optional exemplary embodiment shown in  FIG. 10D , there may be a conformal dielectric layer  1014  deposited prior to deposition of the conformal titanium nitride liner  1004  and conformal layer  1006 . The top semiconductor substrate  104  is then flipped over, bonded to the bottom semiconductor substrate  102  and then thinned as described previously. As a result of the thinning, the bottom  1012  of filled aperture  1002  has sufficient optical contrast from semiconductor substrate  104  to be visible to photolithography equipment as described previously. As shown in  FIG. 10E , the bottom  1012  of filled aperture  1002  extends above the top semiconductor substrate  104  but bottom  1012  of filled aperture  1002  may also be flush with top semiconductor substrate  104  or remain covered by a thin layer of semiconductor substrate  104  as shown, for example, in  FIG. 11 . During the thinning process, the liner layer  1004  or conformal dielectric layer  1014  may be removed to expose the conformal layer  1006 . 
     In the above embodiments, the optional liner layer was stated to be titanium nitride. In other exemplary embodiments, the optional liner layer may also be a combination of tantalum and tantalum nitride. In addition to the optional liner, the conformal dielectric layer may be used to increase the fracture strength of the semiconductor material of semiconductor base  116 . 
     Tungsten is the preferred material for the filled apertures because tungsten provides excellent contrast for backside imaging and alignment. In this regard, the optional liner layer or conformal dielectric (if present) is preferably removed during the thinning of top semiconductor substrate  104  to expose the tungsten in the filled apertures. A problem in using tungsten for the filled apertures is that it is a high stress material which may result in significant substrate bow making subsequent substrate processing difficult. Accordingly, when tungsten is utilized in the filled apertures, the filled apertures are only partially filled which provides the advantage of high contrast without causing substrate bow. 
     In addition to tungsten, other materials to partially or entirely fill the filled apertures include but are not limited to polycrystalline silicon, oxide, oxide/nitride, silicides, copper, tantalum/tantalum nitride, ruthenium and titanium/titanium nitride. 
     A last exemplary embodiment is illustrated in  FIGS. 12A to 12C  wherein the apertures are not filled. Referring first to  FIG. 12A  apertures  1202  (vias or trenches) are conventionally etched in top semiconductor substrate  104 . In this embodiment, the aperture  1202  remains unfilled. Next, a dielectric layer  1204  (such as dielectric layer  120  in  FIG. 1 ) is deposited over the top semiconductor substrate  104  to pinch off the aperture  1202  as shown in  FIG. 12B . The top semiconductor substrate  104  is then flipped over, bonded to semiconductor substrate  102  and then thinned as described previously. As a result of the thinning, the bottom  1206  of unfilled aperture  1202  now has sufficient optical contrast from substrate  104  to be visible to photolithography equipment as described previously. As shown in  FIG. 12C , the bottom  1206  of unfilled aperture  1202  is covered by a thin layer  1208  of substrate  104 . The thin layer  1208  should have a thickness in the range of 200 to 5000 angstroms. 
     It will be apparent to those skilled in the art having regard to this disclosure that other modifications of the exemplary embodiments beyond those embodiments specifically described here may be made without departing from the spirit of the invention. Accordingly, such modifications are considered within the scope of the invention as limited solely by the appended claims.

Technology Category: 5