Taiwan Semiconductor Manufacturing Comp. Ltd.

Chu-Wei Hu

Chung-Te Lin

Kuo-Hua Pan

Jiue-Wen Weng

So-Wein Kuo

Jine-Wen Weng

Hsin-Chi Chen

Tsu Shih

Cheng-Ming Wu

Hsien-Chin Lin

Kai Tzeng

Ruey-Yun Shiue

Chen Cheng Chou

Chin-Shan Hou

Chin-Hsiung Ho

So Wein Kuo

Chu-Sheng Lee

Jiue Wen Weng

Ruey Yun Shiue

Jung-Lieh Hsu

Kuei-Yuam Hsu

Defining an oxide define region (ODR) without using a photomask is disclosed. Pad oxide and a stop layer are deposited over peaks of a substrate of a semiconductor wafer. The pad oxide may be silicon oxide, whereas the stop layer may be silicon nitride. Oxide, such as high-density plasma (HDP) oxide, is deposited over the pad oxide, the stop layer, and valleys of the substrate of the semiconductor wafer. A hard mask, such as silicon nitride, is deposited over the oxide, and photoresist is deposited over the hard mask. The photoresist is etched back until peaks of the hard mask are exposed. The peaks of the hard mask and the oxide underneath are etched through to the stop layer, and the photoresist is removed. Chemical-mechanical planarization (CMP) can then be performed on the hard mask that remains and the oxide underneath through to the stop layer, and the stop layer removed.

Photoresist mask-free oxide define region (ODR)

A method for reducing peeling of a cross-linked polymer passivation layer in a solder bump formation process including providing a multi-level semiconductor device formed on a semiconductor process wafer having an uppermost surface comprising a metal bonding pad in electrical communication with underlying device levels; forming a layer of resinous pre-cursor polymeric material over the process surface said resinous polymeric material having a glass transition temperature (Tg) upon curing; subjecting the semiconductor process wafer to a pre-curing thermal treatment temperature below Tg for a period of time; and, subjecting the semiconductor process wafer to at least one subsequent thermal treatment temperature above Tg for a period of time to form an uppermost passivation layer.

Method to prevent passivation layer peeling in a solder bump formation process

A method for creating a self-aligned channel implant with elevated source/drain areas. Forming a thin dielectric layer on top of a silicon substrate, a thick layer of oxide is deposited over this dielectric. An opening is exposed and etched through the layer of oxide, through the dielectric and into the underlying silicon substrate creating a shallow trench in the substrate. By performing the channel implant LDD implant, pocket implant, forming the gate spacers and electrode, removing the thick layer of oxide and forming the S/D regions a gate electrode has been created with elevated S/D regions. By forming the gate spacers, performing channel implant, forming the gate electrode, removing the thick layer of oxide and performing S/D implant a gate electrode has been created with elevated S/D regions and disposable spacers. By forming the gate spacers and the gate electrode, removing the thick layer of oxide and performing S/D implant a gate electrode has been created with elevated S/D regions and spacers where the gate poly protrudes above the spacers thus enhancing the formation of silicide.

Self aligned channel implant, elevated S/D process by gate electrode damascene

A sacrificial semiconductor feature for preventing corrosion that can result during chemical-mechanical planarization (CMP) is disclosed. A semiconductor device of the invention is fabricated at least in part by performing CMP. The device includes a desired semiconductor feature and a sacrificial semiconductor feature. The desired semiconductor feature may have an unbalanced geometric pattern that includes a metallic line ending in at least one tip. The at least one tip is susceptible to corrosion resulting from performing CMP. The sacrificial semiconductor feature is preferably located off the metallic line of the desired semiconductor feature. The sacrificial semiconductor feature attracts charge induced during CMP that is otherwise attracted by the at least one tip of the desired semiconductor feature. The presence of the sacrificial semiconductor feature thus substantially prevents corrosion of the desired semiconductor feature, including its tip(s).

Sacrificial feature for corrosion prevention during CMP

A new method of forming selective salicide is described, whereby low resistance salicide is formed on exposed MOSFET CMOS, narrow polysilicon gates and lightly doped source/drains (LLD) without affecting device electrical performance. This invention describes a selective salicide process forming titanium salicide on exposed MOSFET CMOS devices using ion implantation for effective ion mixing between a two-step titanium deposition process. First, a thin layer of titanium is deposited on exposed polysilicon gate and exposed lightly doped source/drain (LLD) regions. Second, a low energy ion implantation of Si&plus; is performed with peak dose targeted to be just below the Ti/Si interface. Third, an initial rapid thermal anneal (RTA) is performed followed by a selective etch to remove unwanted, excess titanium. The final step is another rapid thermal anneal (RTA) to fully convert the silicide from C49 crystal structure to the preferred C54 structure, for low resistivity. Hence, low resistivity self-aligned silicide is formed on narrow polygates and lightly doped source/drains (LLD) without affecting device electrical performance.

Ion mixing between two-step titanium deposition process for titanium salicide CMOS technology

A method of forming aluminum guard structures in copper interconnect structures, used to protect the copper interconnect structures from a laser write procedure, performed to an adjacent copper fuse element, has been developed. The method features forming guard structure openings in an upper level of the copper interconnect structures, in a region adjacent to a copper fuse element. Deposition and patterning of an aluminum layer result in the formation of aluminum guard structures, located in the guard structure openings. The aluminum guard structures protect the copper interconnect structures from the oxidizing and corrosive effects of oxygen, fluorine and water ions, which are generated during a laser write procedure, performed to the adjacent copper fuse element.

Method of forming an aluminum protection guard structure for a copper metal structure

A process for forming a dual damascene opening, in a composite insulator layer, comprised of an overlying, wide diameter opening, used to accommodate a metal interconnect structure, and comprised of an underlying, narrow diameter opening, used to accommodate a metal via structure, has been developed. The process features the use of conventional photolithographic and anisotropic dry etching procedures, used to create an initial dual damascene opening, in the composite insulator layer. The subsequent formation of insulator spacers, on the vertical sides of the initial dual damascene opening, however, results in a final dual damascene opening, featuring a diameter smaller than the diameter displayed with the initial dual damascene opening.

Dual damascene process flow for a deep sub-micron technology

A method for forming both n and p wells in a semiconductor substrate using a single photolithography masking step, a non-conformal oxide layer and a chemical-mechanical polish step. A screen oxide layer is formed on a semiconductor substrate. A barrier layer is formed on the screen oxide layer. The barrier layer is patterned to form a first opening in the barrier layer over regions of the substrate where first wells will be formed. We implant impurities of a first conductivity type into the substrate to form first wells. In a key step, a non-conformal oxide layer is formed over the first well regions and the barrier layer. It is critical that the non-conformal oxide layer formed using a HDPCVD process. The non-conformal oxide layer is chemical-mechanical polished stopping at the barrier layer. The barrier layer is removed using a selective etch, to form second openings in the remaining non-conformal oxide layer over areas where second well will be formed in the substrate. Using the remaining non-conformal oxide as a mask, we implant impurities of the second conductivity type through the second openings to form second wells. The remaining non-conformal oxide layer and the screen oxide layer are removed.

Method for forming n and p wells in a semiconductor substrate using a single masking step

A method of forming a FET with an having a self-aligned pocket implant, comprising the following steps. A substrate is formed having a substrate dielectric layer thereon and a first oxide layer over the substrate dielectric layer. The first oxide layer having an upper surface. A trench is formed through the oxide layer, the substrate dielectric layer, and partially through the substrate. The trench having a bottom and side walls. A second oxide layer is formed along the bottom and said side walls of said trench within the substrate. A dopant is selectively ion implanted into the substrate is achieved to form lightly doped layers adjacent the side walls of the trench within the substrate. A self-aligned channel implant and a pocket implant are ion implanted at predetermined respective depths in the substrate below the trench bottom is achieved. Side-wall spacers on the side walls of the trench are then formed with the side-wall spacers each having a top surface below the upper surface of the first oxide layer. A gate dielectric layer is formed on the bottom of the trench between the side-wall spacers. A planarized gate electrode is formed that has an upper surface substantially coextensive with the upper surface of the first oxide layer. The first oxide layer and the substrate dielectric layer are removed. A dopant is ion implanted into the substrate to form heavily doped layers adjacent the side wall spacers.

Method for forming a MOS device with an elevated source and drain, and having a self-aligned channel input

A new method for forming polysilicon lines using a SiON anti-reflective coating during photolithography wherein a thin oxide protection layer is formed over the polysilicon sidewalls and active area surfaces after etching to prevent damage caused by removal of the SiON in the fabrication of integrated circuits is achieved. A gate oxide layer is provided on the surface of a silicon substrate. A polysilicon layer is deposited overlying the gate oxide layer. A SiON anti-reflective coating layer is deposited overlying the polysilicon layer. A photoresist mask is formed over the SiON anti-reflective coating layer. The SiON anti-reflective coating layer, polysilicon layer, and gate oxide layer are etched away where they are not covered by the photoresist mask to form polysilicon lines. The polysilicon lines and the silicon substrate are oxidized to form a protective oxide layer on the sidewalls of the polysilicon lines and on the surface of the silicon substrate. The SiON anti-reflective coating layer is removed wherein the protective oxide layer protects the polysilicon lines and the silicon substrate from damage to complete fabrication of polysilicon lines in the manufacture of an integrated circuit device.

Growing community of inventors

Taichung, Taiwan

Chu-Wei Hu