Method of manufacturing semiconductor device
10325780 ยท 2019-06-18
Assignee
Inventors
Cpc classification
H01L21/02321
ELECTRICITY
H01L21/02282
ELECTRICITY
H01L21/76826
ELECTRICITY
H01L21/76814
ELECTRICITY
H01L21/02359
ELECTRICITY
International classification
Abstract
There is provided a method of manufacturing a semiconductor device, which includes: supplying a raw material for polymerization to a porous low dielectric constant film formed on a substrate for manufacturing a semiconductor device, and filling holes formed in the porous low dielectric constant film with a polymer having a urea bond; subsequently, forming a pattern mask for etching on a surface of the porous low dielectric constant film; subsequently, etching the porous low dielectric constant film; subsequently, removing the pattern mask; and heating the substrate to depolymerize the polymer.
Claims
1. A method of manufacturing a semiconductor device, comprising: supplying a raw material for polymerization to a porous low dielectric constant film formed on a substrate for manufacturing a semiconductor device, and filling holes formed in the porous low dielectric constant film with a polymer having a urea bond; subsequently, forming a pattern mask for etching on a surface of the porous low dielectric constant film; subsequently, etching the porous low dielectric constant film; subsequently, removing the pattern mask; and heating the substrate to depolymerize the polymer, wherein the step of filling includes: impregnating a liquid or mists of isocyanate into the porous low dielectric constant film; supplying a moisture to the porous low dielectric constant film; hydrolyzing the isocyanate to produce an amine; and heating the substrate to cause the isocyanate and the amine to be subjected to a polymerization reaction.
2. The method of claim 1, wherein the step of producing an amine includes: impregnating the liquid or the mists of the isocyanate into the porous low dielectric constant film and subsequently, setting an atmosphere in which the substrate is placed to a water vapor atmosphere.
3. The method of claim 1, wherein the step of impregnating a liquid of isocyanate into the porous low dielectric constant film includes sweeping off an excess liquid of the isocyanate existing on a surface of the substrate by rotating the substrate.
4. The method of claim 1, wherein the step of heating the substrate to depolymerize the polymer is performed after the step of removing the pattern mask.
5. The method of claim 1, wherein the porous low dielectric constant film is an insulating film containing silicon, carbon and oxygen.
6. The method of claim 1, wherein the step of heating the substrate to depolymerize the polymer is performed by heating the substrate at a temperature between 300 degrees C. and 400 degrees C.
7. A method of manufacturing a semiconductor device, comprising: supplying a raw material for polymerization to a porous low dielectric constant film formed on a substrate for manufacturing a semiconductor device, and filling holes formed in the porous low dielectric constant film with a polymer having a urea bond; subsequently, forming a pattern mask for etching on a surface of the porous low dielectric constant film; subsequently, etching the porous low dielectric constant film; subsequently, removing the pattern mask; and heating the substrate to depolymerize the polymer, wherein the step of filling includes: sequentially diffusing one and the other of a vapor of an isocyanate and a vapor of an amine into the porous low dielectric constant film; and heating the substrate to cause the isocyanate and the amine to be subjected to a polymerization reaction.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present disclosure, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the present disclosure.
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DETAILED DESCRIPTION
(20) Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, systems, and components have not been described in detail so as not to unnecessarily obscure aspects of the various embodiments.
(21) An embodiment in which a semiconductor device manufacturing method according to the present disclosure is applied to a process of forming wirings of a semiconductor device by using dual damascene will be described below.
(22) A low dielectric constant film 20 as an interlayer insulating film is formed on the etching stopper film 13. In this embodiment, an SiOC film is used as the low dielectric constant film 20. The SiOC film is formed by, for example, plasmarizing diethoxymethylsilane (DEMS) and using a CVD method. The low dielectric constant film 20 is porous. In
(23) In the method of this embodiment, as shown in
(24) In this embodiment, the holes 21 in the low dielectric constant film 20 are filled with a polymer having a urea bond (polyurea), which is a filling material, as follows. As a method for producing the polyurea, there is a method such as copolymerization as described later, but in this embodiment, a method of producing a polymer by self-polymerization will be described.
(25) First, isocyanate (liquid), which is a raw material of self-polymerization, is impregnated into the low dielectric constant film 20 (
(26) An example of the isocyanate may include an alicyclic compound, an aliphatic compound, an aromatic compound or the like. An example of the alicyclic compound may include 1,3-bis (isocyanatemethyl) cyclohexane (H6XDI) as shown in
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(28) For example, an apparatus shown in
(29) Subsequently, the wafer W is kept in a heating atmosphere of 80 degrees C. and a water vapor atmosphere (of relative humidity 100%) so that the water vapor permeates into the low dielectric constant film 20.
(30) For example, an apparatus as shown in
(31) In some embodiments, instead of providing the water vapor generator 42 and the water vapor discharger 43 as an apparatus for performing the water vapor process, a flat container with a lid may be provided above the mounting table 45 and may be heated in a state where water is accommodated in the container so that the interior of the processing container 41 is kept in the water vapor atmosphere. In this case, the container is closed by the lid while the wafer W is loaded/unloaded.
(32) Since the H6XDI has been already impregnated into the low dielectric constant film 20, when the water vapor permeates into the low dielectric constant film 20, hydrolysis occurs as described above and a polymerization reaction occurs immediately to produce polyurea. Therefore, the holes 21 in the low dielectric constant film 20 are fully filled with the polyurea. In
(33) Subsequently, the wafer W is heated to remove residue present in the low dielectric constant film 20 (
(34) In this way, the holes 21 of the low dielectric constant film 20 are filled with the polyurea. Subsequently, a process of forming a via hole and trench (wiring-burying groove) in the low dielectric constant film 20 is performed. First, as shown in
(35) Subsequently, a masking film 62 serving as a mask used to etch the via hole is formed on the low dielectric constant film 20 and the hard mask 61. Further, an antireflection film 63 and a resist film 64 are stacked in this order on the masking film 62 (
(36) Then, the resist film 64 is subjected to exposure and development processes so that the resist pattern having an opening 641 formed in a portion corresponding to the via hole is formed (
(37) Subsequently, by using the masking film 62 as an etching mask, the low dielectric constant film 20 is etched to form a via hole 201 (
(38) Thereafter, the etching stopper film 13 at the bottom of the via hole 201 is etched away. In the case where the etching stopper film 13 is, for example, a SiC film, the etching may be performed by plasma obtained by plasmarizing a CF.sub.4 gas, for example. Subsequently, the masking film 62 is ashed away by plasma obtained by plasmarizing an oxygen gas (
(39) Thereafter, similar to the process of forming the via hole 201, the low dielectric constant film 20 is etched using the hard mask 61 to form a trench 202 in a region surrounding the via hole 201 (
(40) In the above, it is necessary to carry out the respective processes performed thus far at a temperature lower than the temperature at which the polyurea is depolymerized.
(41) After the via hole 201 and the trench 202 are formed in the low dielectric constant film 20 in this way, the polyurea which is a filling material with which the holes 21 of the low dielectric constant film 20 are filled is removed (
(42) The low dielectric constant film 20 from which the polyurea has been removed returns to the original porous film. Subsequently, the via hole 201 and the trench 202 are filled with copper, and an excessive copper is removed by CMP (Chemical Mechanical Polishing) to form a copper wiring 70, thereby forming a circuit portion of the upper layer side (
(43) In the above embodiment, the isocyanate and the moisture are sequentially supplied onto the low dielectric constant film 20 to fill the holes 21 in the low dielectric constant film 20 with the polyurea which is a polymer having a urea bond. In this state, the low dielectric constant film 20 is etched to form the via hole 201 and the trench 202, and the etching mask is ashed. Therefore, in this embodiment, since the low dielectric constant film 20 is protected by the polyurea at the time of etching and ashing performed as the plasma treatment, it is possible to suppress damage to the low dielectric constant film 20. In addition, since the polyurea is depolymerized at a temperature of about 300 degrees C., the polyurea can be removed from the low dielectric constant film 20 without adversely affecting the element portions already formed on the wafer W, particularly the copper wiring. Further, the polyurea can be removed merely only by the heating treatment. Thus, the process is simple.
(44) In the above embodiment, the isocyanate is spin-coated on the wafer W. However, mists of isocyanate may be supplied in a state where the wafer W remains stationary.
(45) In the above embodiment, a polyurea film is produced by the self-polymerization of the isocyanate. However, as shown in an example in
(46) In this case, for example, a method may be employed in which a liquid which is one of isocyanate and amine is supplied onto the wafer W by the aforementioned spin coating method to allow the liquid to permeate into the low dielectric constant film, and subsequently, the other liquid of isocyanate and amine is similarly supplied onto the wafer W by the aforementioned spin coating method to allow the other liquid to permeate into the low dielectric constant film. In addition, the isocyanate and the amine may be alternately supplied multiple times so that they can be sequentially supplied onto the wafer W in the form of gas (vapor). In this case, for example, vapor of the isocyanate is diffused into and adsorbed onto the holes of the low dielectric constant film, and subsequently, vapor of the amine is diffused into the holes to cause a polymerization reaction. Such action is repeated so as to fully fill the holes with the polyurea film.
(47) The polyurea itself is a solid and cannot be liquefied. Thus, as described above, a method of separately supplying a raw material of the polyurea to a film to produce the polyurea in the film, is employed.
(48) In a method using vapor of raw material monomers, vapor pressures of the raw material monomers may be far apart from each other, for example by one digit or more. This is because, with a combination in which the vapor pressures are close to each other, for example, when the amine is diffused into the holes of the low dielectric constant film, it may be adsorbed onto the surface of the holes, which deteriorates the efficiency of reaction with the isocyanate.
(49) An example of the combination in which a difference in the vapor pressures of isocyanate and amine is of one digit or more may include a combination of isocyanate and amine in which a skeleton molecule obtained by removing an isocyanate functional group from the isocyanate is the same as a skeleton molecule obtained by removing an amine functional group from the amine, namely, the isocyanate and the amine have the same skeleton molecule. For example, the vapor pressure of H6XDA to which the amine functional group is bonded is higher by one digit or more than the vapor pressure of H6XDI having the same skeleton molecule as the H6XDA to which the isocyanate functional group is bonded.
(50) Further, as shown in
(51) Furthermore, as shown in
(52) Further, the raw material monomers having a urea bond may be polymerized to obtain a polyurea film. In this case, the raw material monomers can be supplied onto the low dielectric constant film in the form of liquid, mist or vapor.
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Examples
(54) A low dielectric constant film formed of a SiOC film was formed on a bare wafer and the above-described operation shown in
(55) TABLE-US-00001 TABLE Before filling After filling After removal Film thickness (nm) 193.7 194.3 196.0 Refractive index 1.303 1.445 1.286 Electrical capacity 73 91 68 (pF) Dielectric constant 2.2 2.5 2.1
(56) In addition, absorption spectra were measured for each of the low dielectric constant film before being filled with polyurea, the low dielectric constant film filled with polyurea, and the low dielectric constant film with the polyurea removed therefrom were measured. The measurement results are as shown in
(57) In addition, photographs of the low dielectric constant films before filling and after filling, which were taken by a scanning microscope, are shown in
(58) It can be seen from the above that, when the low dielectric constant film is filled with polyurea, the film quality is slightly changed as the dielectric constant slightly increases, but the low dielectric constant film returns to the original film quality by depolymerizing and removing the polyurea.
(59) In particular, considering measurement errors and the like, it can be said that the dielectric constant is not changed at all. In addition, it is supported by the characteristic diagram of the absorption spectra that the holes in the low dielectric constant film are filled with the polyurea by the method described in the above embodiment and that the polyurea is removed so that it is not left in the low dielectric constant film at all.
(60) In addition, in comparison between the photographs of
(61) According to the present disclosure in some embodiments, a raw material for polymerization is supplied to a low dielectric constant film, and holes formed in the low dielectric constant film are filled with a polymer having a urea bond. An etching is performed and subsequently, a substrate is heated to depolymerize the polymer. Therefore, when etching the low dielectric constant film, it is protected by the polymer. This suppresses damage to the low dielectric constant film. In addition, a polymer having a urea bond is depolymerized at a low temperature (400 degrees C. or less). Thus, when removing the polymer, there is no possibility of adversely affecting element portions already formed on the substrate. Further, it is possible to easily remove the polymer from the low dielectric constant film.
(62) While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosures. Indeed, the embodiments described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the disclosures. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosures.