Patent Document

BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     Generally, the present disclosure relates to the manufacture of sophisticated semiconductor devices, and, more specifically, to a serial capacitor device with a middle electrode contact and methods of making such a capacitor device. 
     2. Description of the Related Art 
     In addition to the large number of transistor elements, a plurality of passive circuit elements, such as capacitors, are typically formed in integrated circuits that are used for a plurality of purposes, such as charge storage for storing information, for decoupling and the like. Decoupling in integrated circuits is an important aspect for reducing the switching noise of the fast switching transistors, since the decoupling capacitor may provide energy at a specific point of the circuitry, for instance at the vicinity of a fast switching transistor, and thus reduce voltage variations caused by the high transient currents which may otherwise unduly affect the logic state represented by the transistor. 
     Due to the decreased dimensions of circuit elements, not only the performance of the individual transistor elements may be increased, but also their packing density may be improved, thereby providing the potential for incorporating increased functionality into a given chip area. For this reason, highly complex circuits have been developed, which may include different types of circuits, such as analog circuits, digital circuits and the like, thereby providing entire systems on a single chip (SoC). Furthermore, in sophisticated micro-controller devices and other sophisticated devices, an increasing amount of storage capacity may be provided on chip with the CPU core, thereby also significantly enhancing the overall performance of modern computer devices. For example, in typical micro-controller designs, different types of storage devices may be incorporated so as to provide an acceptable compromise between die area consumption and information storage density versus operating speed. For example, static RAM memories may be formed on the basis of registers, thereby enabling an access time determined by the switching speed of the corresponding transistors in the registers. Typically, a plurality of transistors may be required to implement a corresponding static RAM cell, thereby significantly reducing the information storage density compared to, for instance, dynamic RAM (DRAM) memories including a storage capacitor in combination with a pass transistor. Thus, a higher information storage density may be achieved with DRAMs, although at a reduced access time compared to static RAMs, which may nevertheless render dynamic RAMs attractive in complex semiconductor devices. 
     Complex integrated circuit devices typically include a memory array, such as an embedded DRAM array, and other non-memory circuits, e.g., logic circuits (such as microprocessors), located outside of the memory array. One problem associated with manufacturing such complex devices is that some designers and manufacturing engineers tend to treat the regions outside the memory array and the memory array itself as completely separate items, each with their own unique design rules and process flows. As a result, in some cases, manufacturing such complex devices is not as cost-effective or efficient as it could be. For example, by independently focusing on one region to the exclusion of the other, additional manufacturing operations may be performed only in that one region, which tends to require additional manufacturing time, makes the resulting device more costly, and may lead to decreased product yields. 
     In recent years, as the integration density of semiconductor devices increases, the area occupied by individual devices continues to decrease. Specifically, a capacitor for storing data of a dynamic random access memory (DRAM) is required to have sufficient capacitance irrespective of the decrease in the area occupied by the capacitor. Accordingly, metal-insulator-metal (MIM) capacitors, in which a lower electrode and an upper electrode are formed of metal and separated by a layer of insulating material, have been used in many integrated circuit products. Additionally, MIM capacitors have been used extensively in semiconductor devices that perform analog-to-digital conversions and digital-to-analog conversions. Conversion between analog signals and digital signals requires that capacitors employed in such conversion processes be stable, i.e., the capacitance of the capacitor must be relatively stable over a range of applied voltages and temperatures. The capacitance of capacitors with polysilicon electrodes tends to be relatively unstable as the capacitance of such capacitor structures tends to vary with changes in temperature and applied voltage. Accordingly, capacitors with polysilicon electrodes are typically not used for such conversion applications. 
     In forming the upper and lower metal electrodes of a typical MIM capacitor, an etching process is typically performed to pattern a metal layer. However, as the integration density of semiconductor devices has increased over the recent years, it has become more difficult to etch such metal layers. In particular, copper, which has good electromigration resistance and a desirable low resistivity, is very difficult to etch. Accordingly, various methods for forming the upper and lower metal electrodes through a damascene process, a process which does not involve etching a metal layer, has been proposed. See, for example, U.S. Pat. No. 6,649,464. A copper damascene process generally comprises forming a trench for a copper structure in an insulation layer, forming a sufficient amount of copper to overfill the trench, and removing the excess copper from the substrate, thereby leaving the copper structure in the trench. However, the damascene process used in forming copper-based capacitors and conductive lines and vias is a very time-consuming, expensive, multiple step process where chances for creating undesirable defects always exists. 
     As noted above, it is not uncommon for a typical integrated circuit product to contain separate regions or areas where logic circuits and circuits requiring capacitors (memory circuits) are formed. As device dimensions have continued to shrink, the area or plot space allotted for forming conductive contact structures and metal lines and vias has continued to decrease as well. In some cases, in so-called “back-end-of-line” processing, metal hard mask layers are employed as etch masks instead of traditional photoresist masks so as to increase etch selectivity between the etch mask and the dielectric material and to enable the more accurate formation of openings for conductive structures, like conductive vias formed using a damascene process. 
     The present disclosure is directed to a high density serial capacitor device and methods of making such a capacitor device. 
     SUMMARY OF THE INVENTION 
     The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later. 
     Generally, the present disclosure is directed to a capacitor device and methods of making such a capacitor device. In one illustrative embodiment, the capacitor includes, among other things, a bottom electrode and a top electrode positioned above the bottom electrode. The top electrode and the bottom electrode are conductively coupled to one another. A middle electrode is positioned between the bottom electrode and the top electrode. A lower dielectric layer is positioned between the bottom electrode and the middle electrode. An upper dielectric layer is positioned between the middle electrode and the top electrode. A first contact is conductively coupled to the top electrode. A second contact is conductively coupled to the middle electrode. 
     Another illustrative capacitor that is disclosed herein includes, among other things, a bottom electrode and a top electrode positioned above the bottom electrode. The top electrode and the bottom electrode are conductively coupled to one another. A middle electrode is positioned between the bottom electrode and the top electrode. The middle electrode includes an extension portion that is coplanar with the top electrode. A lower dielectric layer is positioned between the bottom electrode and the middle electrode. An upper dielectric layer is positioned between the middle electrode and the top electrode. An isolation region of dielectric material is formed above a portion of the extension region and laterally disposed between the extension region and the top electrode. A first contact is conductively coupled to the top electrode. A second contact is conductively coupled to the middle electrode. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which: 
         FIGS. 1A-1P  depict various illustrative methods of forming an illustrative embodiment of a high density serial capacitor device described herein. 
     
    
    
     While the subject matter disclosed herein is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION 
     Various illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. 
     The present subject matter will now be described with reference to the attached figures. Various structures, systems and devices are schematically depicted in the drawings for purposes of explanation only and so as to not obscure the present disclosure with details that are well known to those skilled in the art. Nevertheless, the attached drawings are included to describe and explain illustrative examples of the present disclosure. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase. 
     The present disclosure is directed to a serial capacitor device with a middle electrode contact and methods of making such a capacitor device. As will be readily apparent to those skilled in the art upon a complete reading of the present application, the present method is applicable to a variety of technologies, e.g., NMOS, PMOS, CMOS, etc., and is readily applicable to a variety of devices, including, but not limited to, logic devices, memory devices, etc. With reference to  FIGS. 1A-1P , various illustrative embodiments of the certain methods and certain devices disclosed herein will now be described in more detail. 
       FIG. 1A  is a simplified view of a portion of an illustrative semiconductor device or product  100  at an early stage of manufacturing. The device  100  was formed above a semiconducting substrate (not shown). At the point of fabrication depicted in  FIG. 1A , the device  100  includes an illustrative first insulating layer  10 , a non-conductive diffusion barrier layer  12  second insulating layer  14 , a hard mask layer  16 , a patterned mask layer  22 , a conductive structure  18 , e.g., a conductive line, and a bottom electrode  20  of what will become a serial capacitor. The conductive structures  18 ,  20  are physically spaced apart in the first insulating layer  10 . The layers  10 ,  12  and the conductive structures  18 ,  20  are part of a first metallization layer  21 , while the other materials shown in  FIG. 1A  will become part of a second metallization layer  23 . The layer  12  is the uppermost barrier layer of the first metallization layer  21 . The metallization layers  21 ,  23  are intended to be representative in nature as they may be at any level of the device  100 . For example, the metallization layer  21  may be the so-called “contact” or “CA” layer or it may be the so-called “metal-1” or “M1” that constitutes the first level of the general wiring circuits for the device  100 . As a specific example, the metallization layer  21  may be the CA layer, while the metallization layer  23  may be the M1 layer. As another example, the metallization layer  21  may be the third general metallization layer of the device  100 , while the metallization layer  23  may be the fourth general metallization layer of the device  100 . Of course, the device may have any desired number of metallization layers. Thus, when reference is made herein to any metallization layer, it should be understood that such layer may be at any level in an integrated circuit product, and that the novel devices disclosed herein may be formed at any level of an integrated circuit product. 
     The various layers depicted in  FIG. 1A  may be formed from a variety of different materials, and they may be formed by performing a variety of techniques, such as a chemical vapor deposition (CVD), atomic layer deposition (ALD), physical vapor deposition (PVD) or plasma enhanced versions of such processes. The thickness of such layers may also vary depending upon the particular application. For example, in one illustrative embodiment, the first insulating layer  10  may be comprised of a material such as silicon dioxide, silicon oxynitride, low-k silicon dioxide, a low-k material (k value less than 2.7), etc. In one specific example, the first insulating layer  10  may be a layer of silicon dioxide having a thickness of about 400-600 nm that is initially formed by performing a CVD process. As another example, in one illustrative embodiment, the non-conductive diffusion barrier layer  12  may be comprised of a material, such as silicon nitride, NBLoK™, silicon carbon nitride, a nitrogen-doped silicon carbide, etc., that will help prevent or at least reduce any undesirable migration of the conductive materials in the conductive structure  18  and/or the bottom electrode  20 . In one specific example, the non-conductive diffusion barrier layer  12  may be a layer of NBLoK™ having a thickness of about 20-40 nm that is initially formed by performing a CVD process. 
     Continuing with the discussion of  FIG. 1A , in one illustrative embodiment, the second insulating layer  14  may be comprised of a material such as a so-called low-k insulating material (k value less than 2.7), an ultra-low-k insulating material (k value of less than 2.3), silicon dioxide, OMCTS (Octamethyleyelotetrasiloxane) oxide film, etc. In one specific example, the second insulating layer  14  may be a layer of a low-k insulating material having a thickness of about 700-1000 nm that is initially formed by performing a CVD process. In one illustrative embodiment, the hard mask layer  16  may be comprised of a variety of materials such as, for example, a TEOS-based silicon dioxide, silicon nitride, etc. In one specific example, the hard mask layer  16  may be a layer of TEOS-based silicon dioxide having a thickness of about 30-40 nm that is initially formed by performing a CVD process. Among other things, the hard mask layer  16  acts to protect the underlying second layer of insulating material  14 . The patterned mask layer  22  may be comprised of a variety of materials (e.g., a photoresist material, an organic patterning layer, an anti-reflective coating (ARC) layer, or a combination thereof) and it may be formed using known photolithography techniques. 
     Still referring to  FIG. 1A , the schematically depicted conductive structure  18  may be comprised of a variety of conductive materials, such as copper, copper manganese, silver, etc., and it may be formed using a variety of known techniques. In one specific example, the conductive structure  18  is a copper line that is formed using known damascene techniques. The conductive structure  18  may be part of the overall metallization system for the device  100 . Of course, the size, shape and configuration of the conductive structure  18  may vary depending upon the particular application. In one specific example, the conductive structure  18  may have a thickness that ranges from about 40-60 nm. So as not to obscure the present inventions, various details and layers associated with the formation of the conductive structure  18  are not depicted in the drawings. For example, one or more barrier layers (not shown) are typically formed in the trench  19  prior to depositing the conductive material, e.g., copper in the trench  19 . Similarly, the bottom electrode  20  may be comprised of a variety of conductive materials, such as copper, copper manganese, silver, etc., and it may be formed using a variety of techniques. The thickness of the bottom electrode  20  may also vary depending upon the particular application. In one illustrative embodiment, the bottom electrode  20  may be comprised of copper, it may be formed using known damascene techniques, and it may have a thickness of about 40-60 nm. The lateral width of the bottom electrode  20  may also vary depending upon the particular application. Any barrier layers that may be formed as part of the process of forming the bottom electrode  20  are not depicted in  FIG. 1A  so as not to obscure the present subject matter. 
       FIG. 1B  illustrates the product  100  after one or more etching processes were performed through the patterned mask layer  22  to define a recess  24 . Either dry or wet etching processes may be employed in forming the recess  24 . In one illustrative embodiment, the recess  24  was formed by performing dry anisotropic etching processes to define the recess  24 , with appropriate changes in the etch chemistry of such etching processes as may be required to etch through the hard mask layer  16 , the second layer of insulating material  14 , and, optionally, the barrier layer  12 . In some embodiments, the barrier layer  12  may not be removed from the bottom portion of the recess  24 . The size and configuration of the recess  24  may vary depending upon the particular application. 
       FIG. 1C  illustrates the product  100  after one or more deposition processes were performed to form a second hard mask layer  26  and a conductive middle electrode layer  28 . In one illustrative embodiment, the second hard mask layer  26  may be comprised of a variety of materials such as, for example, a TEOS-based silicon dioxide, silicon nitride, etc. In one specific example, the second hard mask layer  26  may be a layer of TEOS-based silicon dioxide having a thickness of about 30-40 nm that is initially formed by performing a CVD process. In one illustrative embodiment, the conductive middle electrode layer  28  may be comprises of a conductive material such as TiN, Ti, TaN, Ta, a combination thereof, or the like. In general, the material of the middle electrode layer  28  is selected to provide etch selectivity for etching the hard mask layers  16 ,  26 , and the insulating material  14 . 
       FIG. 1D  illustrates the product  100  after a patterned mask layer  30  was formed above the middle electrode layer  28 . 
       FIG. 1E  illustrates the product after one or more etch processes were performed through the patterned mask layer  30  to etch the middle electrode layer  28  to define a middle electrode  32  and a mask portion  34  and to remove the patterned mask layer  30 . 
       FIG. 1F  illustrates the product  100  after a plurality of processes was performed. A first deposition process was performed to form a dielectric layer  36  above the middle electrode layer  28  and the mask portion  34 . A second deposition was performed to form a third insulating layer  38 . A planarization process was performed to remove portions of the third insulating layer  38  extending beyond the recess  24 . The dielectric layer  36  may be comprised of a variety of materials such as, for example, a TEOS-based silicon dioxide, silicon nitride, etc. In one specific example, the dielectric layer  36  may be a layer of TEOS-based silicon dioxide having a thickness of about 30-40 nm that is initially formed by performing a CVD process. The third insulating layer  38  may be comprised of a material such as a so-called low-k insulating material (k value less than 2.7), an ultra-low-k insulating material (k value of less than 2.3), silicon dioxide, OMCTS (Octamethyleyelotetrasiloxane) oxide film, etc. In some embodiments, an optional etch process may be performed to recess the third insulating layer  38  to remove the portion disposed above the dielectric layer  36  in the logic region. 
       FIG. 1G  illustrates the product  100  after a patterned mask layer  40  was formed above the third insulating layer  38 . The patterned mask layer  40  defines a hole opening  42  (i.e., having a generally circular cross section) and a bar opening  44  (i.e., extending into the page and having a rectangular cross section). In some embodiments, different combinations of hole openings and bar openings may be employed. 
       FIG. 1H  illustrates the product  100  after an anisotropic etch was performed through the patterned mask layer  40  to define via openings  46 ,  48 . A timed etch process may be employed and terminated at a point corresponding to about 90% of the thickness of the third insulating layer  38 . 
       FIG. 1I  illustrates the product  100  after an etch process was performed to remove the patterned mask layer  40  and a plurality of processes was performed to form a patterned mask layer  50  (e.g., photoresist) above an edge portion of the middle electrode  32 . 
       FIG. 1J  illustrates the product  100  an etch process was performed to define a trench opening  52  in the second insulating layer  14  and a trench opening  54  in the third insulating layer  38 . In some embodiments the etch process may include a timed etch to remove most of the material of the third insulating layer  38  followed by a selective wet etch to clear the remaining portions in the trench  54 . The selective wet etch may result in some undercutting of the patterned mask layer  50 . A portion of the patterned mask layer  50  may be consumed during the etch process. The trench etch is self-aligned in the logic region due to the presence of the middle electrode  32  and the mask portion  34 . 
       FIG. 1K  illustrates the product after a strip process was performed to remove the patterned mask layer  50  and an etch process was performed to etch the barrier layer  12  to expose the conductive structure  18  and the bottom electrode  20 . 
       FIG. 1L  illustrates the product  100  after one or more deposition process were performed to fill the via openings  46 ,  48  and the trench openings  52 ,  54  with a conductive material  56 . The conductive material  56  may include a plurality of layers (not separately shown), such as a barrier layer (e.g., Ta, TaN, Ti, TiN), a seed layer (e.g., copper), and a conductive fill layer (e.g., copper). 
       FIG. 1M  illustrates the device after a planarization process was performed to remove portions of the layers extending above a surface of the second insulating layer  14  to define a logic interconnect  58  including a via  58 V connecting to the conductive structure  18  in the logic region and a MIM series capacitor  60  in the capacitor region. The MIM series capacitor  60  is defined by the bottom electrode  20 , the middle electrode  32 , and a top electrode  62 . A via  62 V couples the top electrode  62  to the bottom electrode  20 . The vias  58 V,  62 V may be hole type vias or bar type vias. The remaining portions of the second hard mask layer  26  (and portions of the barrier layer  12  if not removed in  FIG. 1B ) define the bottom dielectric between the bottom electrode  20  and the middle electrode  32 . The remaining portions of the dielectric layer  36  define the top dielectric between the middle electrode  32  and the top electrode  62 . Since the middle electrode  32  was formed on a sidewall of the recess  24  defined in the second insulating layer  14  (see  FIG. 1C ) an extension portion  64  of the middle electrode  32  is coplanar with the top electrode  62 . An isolation region  65  is formed by the third insulating layer  38  and is defined by the distance  51  between the extension portion  64  and the top electrode  62  is controlled by the width of the patterned mask layer  50  (see  FIG. 1I ). 
       FIG. 1N  illustrates the product  100  after a plurality of processes was performed to define a metallization layer  66  (e.g., M2) above the MIM series capacitor  60  and the logic interconnect  58 . The metallization layer  66  includes a barrier layer  68 , a fourth insulating layer  70 , a middle node interconnect  72  contacting the extension portion  64  of the middle electrode  32 , and a top/bottom node interconnect  74  contacting the top electrode  62 . In one illustrative embodiment, the barrier layer  68  may comprise a material similar to that of the barrier layer  12 , the fourth insulating layer  70  may comprise a material similar to that of the second insulating layer  14 , and the middle node interconnect  72  and the top/bottom node interconnect  74  may comprise a material similar to that of the top electrode  62 . 
       FIG. 1O  is a plan view of the MIM series capacitor  60  wherein cross-hatching has been maintained in an effort to facilitate a better understanding of the structure. Various layers have been omitted so that the overlay relationship between the electrodes  20 ,  32 ,  62  may be visualized. The isolation region  65  separates the extension portion  64  of the middle electrode  32  from the top electrode  62 . A via portion  72 V of a middle node interconnect  72  contacts the extension portion  64 , and a via portion  74 V of a top/bottom node interconnect  74  contacts the top electrode  62  and the bottom electrode  20  through the via  62 V (see  FIG. 1N ). The via portion  72 V is illustrated as a plurality of individual or discreet hole contacts (depicted in dashed lines), while the via portion  74 V is illustrated as being a bar-type via. Of course, if desired, any of the vias  58 V,  62 V,  72 V,  74 V depicted herein may be discreet hole-type features, bar-type features, or some combination thereof. 
       FIG. 1P  illustrates a schematic diagram of the MIM series capacitor  60  defined by the bottom electrode  20 , the middle electrode  32 , and the top electrode  62 . The via  62 V couples the top electrode  62  to the bottom electrode  20 . The remaining portions of the second hard mask layer  26  (and portions of the barrier layer  12  if not removed in  FIG. 1B ) define the bottom dielectric between the bottom electrode  20  and the middle electrode  32 . The remaining portions of the dielectric layer  36  define the top dielectric between the middle electrode  32  and the top electrode  62 . 
     The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.

Technology Category: h