International Business Machines Corporation

Infineon Technologies Ag

Globalfoundries Inc.

Globalfoundries U.S. 2 LLC

Globalfoudries Inc.

Douglas C La Tulipe, Jr

Spyridon Skordas

Kevin R Winstel

Timothy Joseph Dalton

Kaushik Arun Kumar

Kangguo Cheng

Mark Hoinkis

Chih-Chao Yang

Andrew Herbert Simon

Erdem Kaltalioglu

Steffen K Kaldor

Jochen Schacht

Bruce Bennett Doris

Ali Khakifirooz

Lawrence Alfred Clevenger

Charles W Koburger, Iii

Anna Wanda Topol

Wei Lin

Andy Cowley

James Vichiconti

Mark Todhunter Robson

David V Horak

Shom Ponoth

Sampath Purushothaman

Elbert Emin Huang

Yun-Yu Wang

Steven Erik Steen

Tuan Anh Vo

Andrew P Cowley

Larry Clevenger

Clement Hsingjen Wann

Daniel C Edelstein

William R Tonti

Toshiharu Furukawa

Subramanian Srikanteswara Iyer

Terry Allen Spooner

Deepika Priyadarshini

Leathen Shi

David James Frank

John W Golz

Nathaniel C Berliner

Pooja R Batra

John Ulrich Knickerbocker

Haining S Yang

Soon-Cheon Seo

Bing Dang

Paul Stephen Andry

Russell Alan Budd

Pranita Kerber

Pranita Kulkarni

Meikei Ieong

Stephen Mark Rossnagel

Gregory Breyta

Cornelia K Tsang

Albert M Young

Sarah Huffsmith Knickerbocker

Robert E Trzcinski

Markus Naujok

Alex Richard Hubbard

Yi-Hsiung Lin

A metallic dopant element having a greater oxygen-affinity than copper is introduced into, and/or over, surface portions of copper-based metal pads and/or surfaces of a dielectric material layer embedding the copper-based metal pads in each of two substrates to be subsequently bonded. A dopant-metal silicate layer may be formed at the interface between the two substrates to contact portions of metal pads not in contact with a surface of another metal pad, thereby functioning as an oxygen barrier layer, and optionally as an adhesion material layer. A dopant metal rich portion may be formed in peripheral portions of the metal pads in contact with the dopant-metal silicate layer. A dopant-metal oxide portion may be formed in peripheral portions of the metal pads that are not in contact with a dopant-metal silicate layer.

Substrate bonding with diffusion barrier structures

A device includes a semiconductor substrate. A gate stack on the semiconductor substrate includes a gate dielectric layer and a gate conductor layer. Low-k spacers are adjacent to the gate dielectric layer. Raised source/drain (RSD) regions are adjacent to the low-k spacers. The low-k spacers are embedded in an ILD on the RSD regions.

Semiconductor device with a low-K spacer and method of forming the same

The embodiments of the present invention relate generally to the fabrication of integrated circuits, and more particularly to a structure and method for fabricating a 3D integration scheme for multiple semiconductor wafers using an arrangement of intra-wafer through silicon vias (TSVs) to electrically connect the front side of a first integrated circuit (IC) chip to large back side wiring on the back side of the first IC chip and inter-wafer TSVs to electrically connect the first IC chip to a second IC chip.

Combination of TSV and back side wiring in 3D integration

Method and Apparatus so configured for the fabrication of three-dimensional integrated devices. A crystalline substrate within an area of a donor semiconductor wafer is etched. The substrate side is located opposite a device layer and has a buried insulating layer and a substrate thickness. The etching removes at least a substantial portion of the crystalline substrate within the area such that the device layer and the buried insulating layer in the area is to conform to a pattern specific topology on an acceptor surface. The donor semiconductor wafer is supported with a supporting structure that allows the donor semiconductor wafer to flexibly conform to the pattern specific topology within at least a portion of the area after the etching to enable conformality and reliable bonding to the device surfaces of an acceptor wafer to form a three dimensional integrated device.

Three-dimensional integrated circuit device fabrication including wafer scale membrane

A method of forming a high aspect ratio via opening through multiple dielectric layers, a high aspect ratio electrically conductive via, methods of forming three-dimension integrated circuits, and three-dimensional integrated circuits. The methods include forming a stack of at least four dielectric layers and etching the first and third dielectric layers with processes selective to the second and fourth dielectric layers, etching the second and third dielectric layers with processes selective to the first and second dielectric layers. Advantageously the process used to etch the third dielectric layer is not substantially selective to the first dielectric layer.

Method of fabricating ultra-deep vias and three-dimensional integrated circuits using ultra-deep vias

A semiconductor structure including expanded source/drain regions that extend in an opposite direction of a gate electrode is provided. The semiconductor structure includes a stack of a body-containing region and a buried insulator portion, a gate dielectric in contact with a surface of the body-containing region, a gate electrode in contact with the gate dielectric, and a source region and a drain region laterally spaced by, and in contact with, the stack. The semiconductor structure further includes a contact level dielectric layer deposited on surfaces of the source region, the drain region and the buried insulator portion.

Inverted thin channel mosfet with self-aligned expanded source/drain

A bonding layer of a first wafer article is thermally treated and a bonding layer of a second wafer article is thermally treated in accordance with first and second process parameters, respectively prior to bonding the first wafer article with the second wafer article. First and second grid distortion in the first and second wafer articles is measured and a difference is determined between the first and second grid distortions. A prediction is made for maintaining the difference within a prescribed tolerance. At least one of the first process parameters and the second process parameters is conditionally varied in accordance with the prediction. The thermal treating of the first and second wafer articles can then be performed with respect to another pair of the first and second wafer articles prior to bonding to one another through their respective bonding layers.

Reducing wafer bonding misalignment by varying thermal treatment prior to bonding

A method of removing a handler wafer. There is provided a handler wafer and a semiconductor device wafer having a plurality of semiconductor devices, the semiconductor device wafer having an active surface side and an inactive surface side. An amorphous carbon layer is applied to a surface of the handler wafer. An adhesive layer is applied to at least one of the amorphous carbon layer of the handler wafer and the active surface side of the semiconductor device wafer. The handler wafer is joined to the semiconductor device wafer through the adhesive layer or layers. Laser radiation is applied to the handler wafer to cause heating of the amorphous carbon layer that in turn causes heating of the adhesive layer or layers. The plurality of semiconductor devices of the semiconductor device wafer are then separated from the handler wafer.

Handler wafer removal facilitated by the addition of an amorphous carbon layer on the handler wafer

A bonding layer of the first wafer article is thermally treated and a bonding layer of a second wafer article is thermally treated in accordance with first and second process parameters, respectively prior to bonding the first wafer article with the second wafer article. First and second grid distortion in the first and second wafer articles is measured and a difference is determined between the first and second grid distortions. A prediction is made for maintaining the difference within a prescribed tolerance. At least one of the first process parameters and the second process parameters can be conditionally varied in accordance with the prediction. The thermally treating of the first wafer article and the thermally treating of the second wafer article can then be performed with respect to another pair of the first and second wafer articles prior to bonding the another pair of wafer articles to one another through their respective bonding layers.

A method for processing a semiconductor wafer includes applying a release layer to a transparent handler. An adhesive layer, that is distinct from the release layer, is applied between a semiconductor wafer and the transparent handler having the release layer applied thereon. The semiconductor wafer is bonded to the transparent handler using the adhesive layer. The semiconductor wafer is processed while it is bonded to the transparent handler. The release layer is ablated by irradiating the release layer through the transparent handler with a laser. The semiconductor wafer is removed from the transparent handler.

Advanced handler wafer bonding and debonding

A donor wafer containing integrated semiconductor device. The donor wafer has a donor wafer membrane portion that has a device layer and a buried insulating layer. The donor wafer membrane portion has a number of integrated semiconductor devices where each integrated semiconductor device within the plurality of semiconductor devices corresponds to a die formed on the donor wafer. The donor wafer membrane portion has a diameter of at least 200 mm. The donor wafer has a crystalline substrate that is substantially removed from an area of the donor wafer membrane portion such that the device layer and the buried insulating layer of the donor wafer membrane in the area is configured to conform to a pattern specific topology on an acceptor surface. The donor wafer further has a support structure attached to regions of the donor wafer that are outside of the donor wafer membrane portion.

Three-dimensional integrated circuit device using a wafer scale membrane

After formation of a gate electrode, a source trench and a drain trench are formed down to an upper portion of a bottom semiconductor layer having a first semiconductor material of a semiconductor-on-insulator (SOI) substrate. The source trench and the drain trench are filled with at least a second semiconductor material that is different from the first semiconductor material to form source and drain regions. A planarized dielectric layer is formed and a handle substrate is attached over the source and drain regions. The bottom semiconductor layer is removed selective to the second semiconductor material, the buried insulator layer, and a shallow trench isolation structure. The removal of the bottom semiconductor layer exposes a horizontal surface of the buried insulator layer present between source and drain regions on which a conductive material layer is formed as a back gate electrode.

A method for creating an extremely thin semiconductor-on-insulator (ETSOI) layer having a uniform thickness includes: measuring a thickness of a semiconductor-on-insulator (SOI) layer at a plurality of locations; determining a removal thickness at each of the plurality of locations; and implanting ions at the plurality of locations. The implanting is dynamically based on the removal thickness at each of the plurality of locations. The method further includes oxidizing the SOI layer to form an oxide layer, and removing the oxide layer.

Method of creating an extremely thin semiconductor-on-insulator (ETSOI) layer having a uniform thickness

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Guilderland, NY, United States of America

Douglas C La Tulipe, Jr