Process for electroless copper deposition
First Claim
1. A method for forming a conductive material within a feature on a substrate comprising:
- depositing a seed layer selectively onto a bottom surface of a feature on a substrate while sidewalls of the feature remain substantially free of the seed layer during a collimated physical vapor deposition process; and
depositing a copper-containing layer on the seed layer to fill the feature during an electroless deposition process, wherein the seed layer comprises a metal selected from the group consisting of copper, ruthenium, cobalt, tantalum, titanium, tungsten, rhenium, palladium, platinum, nickel, alloys thereof, and combinations thereof and wherein the seed layer is deposited on a barrier layer disposed on the substrate, the barrier layer comprises a material selected from the group consisting of tantalum, tantalum nitride, tantalum silicon nitride, titanium, titanium nitride, titanium silicon nitride, ruthenium, tungsten, tungsten nitride, alloys thereof, derivatives thereof, and combinations thereof.
1 Assignment
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Accused Products
Abstract
Embodiments of the invention provide methods for forming conductive materials within contact features on a substrate by depositing a seed layer within a feature and subsequently filling the feature with a copper-containing material during an electroless deposition process. In one example, a copper electroless deposition solution contains levelers to form convexed or concaved copper surfaces. In another example, a seed layer is selectively deposited on the bottom surface of the aperture while leaving the sidewalls substantially free of the seed material during a collimated PVD process. In another example, the seed layer is conformably deposited by a PVD process and subsequently, a portion of the seed layer and the underlayer are plasma etched to expose an underlying contact surface. In another example, a ruthenium seed layer is formed on an exposed contact surface by an ALD process utilizing the chemical precursor ruthenium tetroxide.
207 Citations
41 Claims
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1. A method for forming a conductive material within a feature on a substrate comprising:
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depositing a seed layer selectively onto a bottom surface of a feature on a substrate while sidewalls of the feature remain substantially free of the seed layer during a collimated physical vapor deposition process; and depositing a copper-containing layer on the seed layer to fill the feature during an electroless deposition process, wherein the seed layer comprises a metal selected from the group consisting of copper, ruthenium, cobalt, tantalum, titanium, tungsten, rhenium, palladium, platinum, nickel, alloys thereof, and combinations thereof and wherein the seed layer is deposited on a barrier layer disposed on the substrate, the barrier layer comprises a material selected from the group consisting of tantalum, tantalum nitride, tantalum silicon nitride, titanium, titanium nitride, titanium silicon nitride, ruthenium, tungsten, tungsten nitride, alloys thereof, derivatives thereof, and combinations thereof. - View Dependent Claims (2)
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3. A method for forming a conductive material within a feature on a substrate, comprising:
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depositing a seed layer selectively onto a bottom surface of a feature on a substrate while sidewalls of the feature remain substantially free of the seed layer during a collimated physical vapor deposition process; and depositing a copper-containing layer on the seed layer to fill the feature during an electroless deposition process, wherein the electroless deposition process comprises exposing the substrate to an electroless solution comprising a copper source and at least one additive selected from the group consisting of an accelerator, a suppressor, a leveler, and combinations thereof, wherein the accelerator is a sulfur-based compound selected from the group consisting of bis(3-sulfopropyl) disulfide, 3-mercapto-1-propane sulfonic acid, derivatives thereof, and combinations thereof.
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4. A method for forming a conductive material within a feature on a substrate, comprising:
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depositing a seed layer selectively onto a bottom surface of a feature on a substrate while sidewalls of the feature remain substantially free of the seed layer during a collimated physical vapor deposition process; and depositing a copper-containing layer on the seed layer to fill the feature during an electroless deposition process, wherein the electroless deposition process comprises exposing the substrate to an electroless solution comprising a copper source and at least one additive selected from the group consisting of an accelerator, a suppressor, a leveler, and combinations thereof, wherein the suppressor is polyethylene glycol, polypropylene glycol, polyoxyethylene-polyoxypropylene copolymer, or derivatives thereof.
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5. A method for forming a conductive material within a feature on a substrate, comprising:
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depositing a seed layer selectively onto a bottom surface of a feature on a substrate while sidewalls of the feature remain substantially free of the seed layer during a collimated physical vapor deposition process; and depositing a copper-containing layer on the seed layer to fill the feature during an electroless deposition process, wherein the electroless deposition process comprises exposing the substrate to an electroless solution comprising a copper source and at least one additive selected from the group consisting of an accelerator, a suppressor, a leveler, and combinations thereof, wherein a surface of the copper-containing layer adjoins the sidewall of the feature at an angle of less than 90°
from the sidewall. - View Dependent Claims (6, 7, 8, 9, 10, 11)
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12. A method for forming a conductive material within a feature on a substrate, comprising:
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depositing a seed layer onto a barrier layer disposed on a substrate during a physical vapor deposition process, wherein the substrate contains a feature having sidewalls and a bottom surface; etching the bottom surface of the feature with a plasma to remove a portion of the seed layer and the barrier layer and to expose a conductive underlayer; and depositing a copper-containing layer on the conductive underlayer while filling the feature during an electroless deposition process. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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28. A method for forming a conductive material within a feature on a substrate, comprising:
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depositing a seed layer onto a barrier layer disposed on a substrate during a physical vapor deposition process, wherein the substrate contains a feature having sidewalls and a bottom surface; and exposing the substrate to an electroless deposition solution to deposit a copper-containing layer over the seed layer, wherein the electroless deposition solution comprises a leveler at a concentration to form a surface of the copper-containing layer adjoining the sidewall of the feature at an angle of less than 90°
from the sidewall. - View Dependent Claims (29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41)
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Specification