Lsi Logic Corporation

Xilinx, Inc.

Lsi Corporation

Joe W Zhao

Wilbur G Catabay

Wei-Jen Hsia

Shumay X Dou

Zhihai Wang

Keith K Chao

Cinti Xiaohua Chen

Xiao-Yu Li

Yongjun Zheng

Nicholas F Pasch

Weidan Li

Zhi-min Ling

David Mark

Feng Wang

Felino E Pagaduan

Mark I Mayeda

An embodiment of an integrated circuit is disclosed. For this embodiment, the integrated circuit includes circuit blocks. At least one transistor of a circuit block of the circuit blocks includes a portion of a semiconductor substrate having a diffusion layer. The circuit block has a relatively high diffusion pattern density as compared with others of the circuit blocks. The diffusion layer has an exposed surface active area constrained responsive to a design rule. The design rule is to limit to a maximum amount the surface active area in order to improve at least one parameter of the at least one transistor selected from a group consisting of an increase in switching speed and a decrease in leakage current of the at least one transistor of the circuit block having the relatively high diffusion pattern density.

Increasing circuit speed and reducing circuit leakage by utilizing a local surface temperature effect

A method of analyzing integrated circuit (IC) product yield can include storing, within a memory of a system comprising a processor, parametric data from a manufacturing process of an IC and determining a measure of non-random variation for at least one parameter of the parametric data using a pattern detection technique. The processor can compare the measure of non-random variation to a randomness criteria and selectively output a notification indicating that variation in the parameter is non-random according to the comparison of the measure of non-random variation to the randomness criteria.

Identifying non-randomness in integrated circuit product yield

An embodiment of the present invention reduces resources needed to estimate the Icc Current Temperature Scaling Factor (ITSF) of a device, and provides a method and apparatus to estimate ITSF from the device speed and performance characteristics which can be measured at room temperature. In one embodiment, a method for estimating the ITSF of an integrated circuit includes: determining a level of propagation delay of a portion of the integrated circuit; and determining an estimated Icc current temperature scaling factor from a correlation between the level of the propagation delay and a modeled Icc current temperature scaling factor.

Estimating Icc current temperature scaling factor of an integrated circuit

A method of evaluating an inline inspection recipe compares the capture rate of metal pattern defects in bounding boxes arising from failed electrical test vectors to the capture rate after the bounding box is shifted. A difference between the first and second capture rates indicates whether the inline inspection recipe is valid for capturing killer defects, or if the inline inspection recipe needs to be adjusted. In a particular example, the electrical test vectors are directed at a selected patterned metal layer of an FPGA (M), and the metal pattern defect data for the selected patterned metal layer is mapped to the bounding box determined by the electrical test vector.

Method of metal pattern inspection verification

Methods for monitoring and improving the fabrication process of integrated circuits using configurable devices are described. In one aspect, the method includes instantiating a test pattern on one or more configurable devices fabricated using the fabrication process, identifying an underperforming region of the configurable devices, and determining if the underperforming region is layout sensitive. At least one of the fabrication process and the layout of the configurable device can then be adjusted based on the determination. In some embodiments, the configurable device may be a programmable logic device, such as a field programmable logic array.

Method for monitoring and improving integrated circuit fabrication using FPGAs

An integrated circuit structure is disclosed wherein the capacitance between nearby conductive portions may be lowered using carbon-containing low k silicon oxide dielectric material, without contributing to the problem of via poisoning, by careful control of the carbon content of the dielectric material in two regions of the integrated circuit structure. The first region comprises the region between adjacent raised conductive lines formed over an underlying insulation layer, where undesirable capacitance may be formed horizontally between such adjacent conductive lines, while the second region comprises the region above the raised conductive lines where vias are normally formed extending upward from the raised conductive lines through the dielectric layer to an overlying layer of metal interconnects. In one embodiment, the carbon-containing low k silicon oxide dielectric material used in the first region between adjacent raised conductive lines has a high carbon content to provide maximum reduction of the dielectric constant of the dielectric material for maximum reduction in the horizontal capacitance developed between horizontally adjacent lines, while the carbon-containing low k silicon oxide dielectric material used in the second region above the raised conductive lines has a reduced carbon content to mitigate poisoning of vias formed through the dielectric material in this second region. In another embodiment both the first and second regions have the same or similar reduced carbon content in the carbon-containing low k silicon oxide dielectric material used in both of the respective first and second regions to thereby provide a carbon content sufficient to lower the undesirable capacitance formed horizontally between said adjacent raised conductive lines in said first region, but insufficient to cause via poisoning in vias formed in said second region.

Low dielectric constant silicon oxide-based dielectric layer for integrated circuit structures having improved compatibility with via filler materials, and method of making same

A dual damascene type of structure of vias and trenches formed using layers of low k dielectric material is disclosed, and a process for making same without damage to the low k dielectric material during removal of photoresist masks used respectively in the formation of the pattern of via openings and the pattern of trench openings in the layers of low k dielectric material. Damage to the low k dielectric material is avoided by forming a first layer of low k dielectric material on an integrated circuit structure; forming a first hard mask layer over the first layer of low k dielectric material; forming over the first hard mask layer a first photoresist mask having a pattern of via openings therein; and then etching the first hard mask layer through the first photoresist mask to form a first hard mask having the pattern of vias openings replicated therein, using an etch system which will also remove the first photoresist mask. The first photoresist mask (the via mask) is, therefore, removed during the formation of the first hard mask, instead of in a separate oxidizing step which would damage the low k dielectric material. Damage to the low k dielectric material during removal of the second photoresist mask (the trench mask) is also avoided by depositing a second layer of low k dielectric material over the first hard mask; forming over the second layer of low k dielectric material a second hard mask layer; forming over the second hard mask layer a second photoresist mask having a pattern of trench openings therein; and then forming the second hard mask by etching the second hard mask layer through the second photoresist resist mask to form a second hard mask having the pattern of trench openings replicated therein, using at etch system which will also remove the second photoresist mask. Thus, the second photoresist mask (the trench mask) is also removed during the formation of the second hard mask, instead of in a separate oxidizing step which would damage the low k dielectric material.

Process for forming trenches and vias in layers of low dielectric constant carbon-doped silicon oxide dielectric material of an integrated circuit structure

A method of forming titanium nitride barrier layers that are highly conformal, have high step coverage and low resistivity through a two stage deposition process is described. Low temperature deposition of titanium nitride barrier layer provides material of high conformity and good step coverage but of high resistivity. High temperature deposition of titanium nitride barrier layer yields material of low resistivity. Thus, a titanium nitride barrier layer deposited in separate steps at low temperature and high temperature by the method of the present invention is particularly suited for use in modern devices of increasing density that are characterized by narrow and deep contact holes.

Method to obtain a low resistivity and conformity chemical vapor deposition titanium film

Provided is a method and composition for obtaining consistent alignment mark profiles with both detectibiliy and detection accuracy for use in conjunction with CMP planarization processes in semiconductor fabrication. The method involves physical vapor deposition of metal over an angled, metal-lined alignment mark trench in the surface of a semiconductor wafer following wafer planarization by CMP. The shape of the trench creates a shadowing effect which produces minimal deposition in the angled region of the trench and overcomes asymmetric metal loss due to attack from slurry accumulating in the trench during CMP. The result is the formation of a reliable and reproducible alignment mark.

Consistent alignment mark profiles on semiconductor wafers using PVD shadowing

The invention comprises a process for forming a dielectric film having a compressive stress exhibited in the layers deposited onto an integrated circuit structure. This process includes depositing a first thin layer of dielectric material onto an integrated circuit structure, then exposing the integrated circuit structure to an elevated temperature. Then a second thin layer of dielectric material is deposited immediately overtop of the first thin layer of dielectric material, and then the integrated circuit structure is again exposed to an elevated temperature. The process is carried out to insure that the composite layer comprising the first and second deposited thin dielectric layers, after heat treatment, exhibits a residual stress which is compressive. The steps of depositing an additional thin dielectric layer and then exposing the semiconductor wafer to an elevated temperature may be repeated until a sufficient composite thickness of dielectric material has been formed, typically about 5000 &angst; to about 10,000 &angst;.

Process to prevent stress cracking of dielectric films on semiconductor wafers

A process is provided for removing etch residues from one or more openings formed in one or more layers of a low dielectric constant insulation material over a copper metal interconnect layer of an integrated circuit structure which includes cleaning exposed portions of the surface of the copper interconnect layer at the bottom of the one or more openings, the process comprising providing an anisotropic hydrogen plasma to cause a chemical reaction between ions in the plasma and the etch residues in the bottom of the one or more opening, including copper oxide on the exposed copper surface, to thereby clean the exposed portions of the copper surface, and to remove the etch residues without sputtering the copper at the bottom of the opening.

Plasma cleaning process for openings formed in at least one low dielectric constant insulation layer over copper metallization in integrated circuit structures

Provided is a method and composition for protecting alignment mark trench walls from attack by CMP slurry accumulating in an alignment mark trench during CMP processing. In a preferred embodiment, a metal organic chemical vapor deposition titanium nitride (MOCVDTiN) layer is deposited over a conventionally applied bulk tungsten layer prior to commencing CMP operations. This MOCVDTiN layer is resistant to CMP slurry attack. As a result, the tungsten trench profile remains a consistent and reliable alignment mark.

Consistent alignment mark profiles on semiconductor wafers using metal

Provided is a method and composition for reducing the rate of, and rendering more uniform the oxidation of alignment mark trench side walls by CMP slurry accumulating in an alignment mark trench during CMP processing. In a preferred embodiment, a nucleation layer of tungsten having an equiaxed grain structure with fine grain size and conformity is deposited over a conventionally applied bulk tungsten layer prior to commencing CMP operations. The fine grain size and equiaxed grain structure of this nucleation layer make it more resistant and more uniform in response to slurry attack. As a result, the tungsten trench profile remains a consistent and reliable alignment mark.

Consistent alignment mark profiles on semiconductor wafers using fine

Described is an improvement in a process wherein integrated circuit structures are formed on a front surface of a silicon substrate and at least one layer of copper is deposited on the front surface of the substrate to form a layer of copper interconnects, and wherein at least some copper is also deposited on the back surface of the substrate during this deposition. The improvement comprises: prior to the end of the formation of the integrated circuit structures, abrasively removing, from the backside of the substrate, copper deposited thereon during the deposition of copper on the front surface. The step of abrasively removing copper from the back side of the substrate is preferably carried out before exposure of the substrate and the copper thereon, including copper deposited on the back side of the substrate, to any subsequent high temperature processing, and preferably, the step of abrasively removing the copper from the backside of the substrate comprises a chemical/mechanical polishing step which leaves a polished surface on the backside of the substrate to facilitate subsequent mounting or packaging of the integrated circuit structures.

Process for abrasive removal of copper from the back surface of a

A process is described for treating damaged surfaces of a low dielectric constant organo silicon oxide insulation layer of an integrated circuit structure to inhibit absorption of moisture which comprises treating such damaged surfaces of said organo silicon oxide insulation layer with a hydrogen plasma. The treatment with hydrogen plasma causes hydrogen to bond to silicon atoms with dangling bonds in the damaged surface of the organo silicon oxide layer to replace organic material severed from such silicon atoms at the damaged surface, whereby absorption of moisture in the damaged surface of the organo silicon oxide layer, by bonding of such silicon dangling bonds with moisture, is inhibited.

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San Jose, CA, United States of America

Joe W Zhao