In-situ capped aluminum plug (CAP) process using selective CVD AL for integrated plug/interconnect metallization
First Claim
1. A method of forming a capped metal plug in a via through a dielectric layer, wherein the via has a floor exposing a deposition enhancing material, comprising the steps of:
- a) selectively chemical vapor depositing a metal on the deposition enhancing material of the via floor to form a plug in the via;
b) physical vapor depositing a sufficient amount of a warm metal over the dielectric layer to substantially planarize any nodules on the dielectric layer, wherein the physical vapor deposited metal has a thickness below about 1200 Å
; and
c) depositing a barrier layer over the physical vapor deposited metal.
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Abstract
The present invention generally provides a method of forming a structure having a selective CVD metal plug with a continuous barrier layer formed thereon. More particularly, the present invention applies a thin layer of warm PVD metal over a selective CVD metal plug and adjacent nodules on the dielectric field to planarize the metal surface. A barrier is then deposited over the planarized metal surface. Therefore, the invention provides the advantages of having (1) void-free, sub-half micron selective CVD metal via plugs and interconnects, and (2) a reduced number of process steps without the use of CMP, and (3) barrier layers over the metal plugs to improve the electromigration resistance of the metal.
61 Citations
22 Claims
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1. A method of forming a capped metal plug in a via through a dielectric layer, wherein the via has a floor exposing a deposition enhancing material, comprising the steps of:
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a) selectively chemical vapor depositing a metal on the deposition enhancing material of the via floor to form a plug in the via; b) physical vapor depositing a sufficient amount of a warm metal over the dielectric layer to substantially planarize any nodules on the dielectric layer, wherein the physical vapor deposited metal has a thickness below about 1200 Å
; andc) depositing a barrier layer over the physical vapor deposited metal. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 20, 21)
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14. A method of forming a via plug through a dielectric layer having barrier layers at each end of the plug, comprising the steps of:
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a) depositing a barrier layer on the top layer of a workpiece; b) forming a dielectric layer over the barrier layer; c) etching a via through the dielectric layer to form a floor exposing the barrier layer; d) selectively chemical vapor depositing a conductive material on the exposed portion of the barrier layer to form a plug in the via; e) physical vapor depositing a sufficient amount of a warm metal over the dielectric layer to substantially planarize any nodules formed by loss of selectivity during plug formation, wherein the warm physical vapor deposited metal has a thickness from about 100 Å
to about 1200 Å
; andf) depositing a barrier cap layer over the warm physical vapor deposited metal. - View Dependent Claims (15, 16, 17, 18, 19, 22)
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Specification