Abstract: An improved process of substrate cleaving and a device to perform the cleaving are disclosed. In the traditional cleaving process, a layer of microbubbles is created within a substrate through the implantation of ions of a gaseous species, such as hydrogen or helium. The size and spatial distribution of these microbubbles is enhanced through the use of ultrasound energy. The ultrasound energy causes smaller microbubbles to join together and also reduces the straggle. An ultrasonic transducer is acoustically linked with the substrate to facilitate these effects. In some embodiments, the ultrasonic transducer is in communication with the platen, such that ultrasound energy can be applied during ion implantation and/or immediately thereafter. In other embodiments, the ultrasonic energy is applied to the substrate during a subsequent process, such as an anneal.

Abstract: The invention provides a method of fabricating a semiconductive device [200]. In this embodiment, the method comprises depositing a hydrocarbon layer [294] over a semiconductive substrate, forming an interconnect structure [295, 297] within the hydrocarbon layer [294], and removing the hydrocarbon layer [294] by sublimation.

Abstract: A method of tailoring the dopant profile of a substrate by utilizing two different dopants, each having a different diffusivity is disclosed. The substrate may be, for example, a solar cell. By introducing two different dopants, such as by ion implantation, furnace diffusion, or paste, it is possible to create the desired dopant profile. In addition, the dopants may be introduced simultaneously, partially simultaneously, or sequentially. Dopant pairs preferably consist of one lighter species and one heavier species, where the lighter species has a greater diffusivity. For example, dopant pairs such as boron and gallium, boron and indium, phosphorus and arsenic, and phosphorus and antimony, can be utilized.

Abstract: Embodiments of this method improve the results of a chemical mechanical polishing (CMP) process. A surface is implanted with a species, such as, for example, Si, Ge, As, B, P, H, He, Ne, Ar, Kr, Xe, and C. The implant of this species will at least affect dishing, erosion, and polishing rates of the CMP process. The species may be selected in one embodiment to either accelerate or decelerate the CMP process. The dose of the species may be varied over the surface in one particular embodiment.

Abstract: A method for detecting defects during semiconductor device processing can include providing a substrate having a semiconductor comprising layer with electrically isolated application and test circuits are formed thereon, directing an electron current inducing beam to the test circuit; measuring a current between the first and the second contact pads in the test circuit; determining an electron beam induced current (EBIC); and identifying one or more defect locations in the test circuit based on the EBIC and a location of the electron beam corresponding to the EBIC. A test circuit can include a plurality of semiconductor devices connected in parallel, a first contact pad coupled to a first terminal of the semiconductor devices, and at least a second contact pad coupled to a substrate terminal associated with the semiconductor devices.

Abstract: Methods for forming dual damascene interconnect structures are provided. The methods incorporate an ashing operation comprising a first ash operation and a second overash operation. The ashing operation is performed prior to etching of an etch stop layer. The operation removes residue from a cavity formed during formation of the interconnect structure and facilitates better CD control without altering the cavity profiles.

Abstract: In accordance with the invention, there are methods of making semiconductor devices. The method can include forming a hard mask layer over a dielectric layer, forming a via through the hard mask layer and the dielectric layer, and depositing an anti-reflective coating in the via and over the hard mask layer. The method can also include etching a trench through the hard mask layer, etching a dummy fill pattern in the hard mask layer to a desired thickness, and etching the trench through the dielectric layer and the dummy fill through the hard mask layer and in the dielectric layer. The method can further include depositing copper in the via and in the trench and removing excess copper using chemical mechanical polishing, wherein the dummy fill in the dielectric layer is of desired reduced depth.

Abstract: In accordance with the invention, there are electron beam inspection systems, electron beam testable semiconductor test structures, and methods for detecting systematic defects, such as, for example contact-to-gate shorts, worm hole leakage paths, holes printing issues, and anomalies in sparse holes and random defects, such as, current leakage paths due to dislocations and pipes during semiconductor processing.

Abstract: Current manufacturing of miniature or micro electronic mechanical optical chemical or biophysical devices utilizes discrete substrates holding one or more said devices. The use of discrete substrates entails several disadvantages with respect to economical manufacturing. This invention is a method of manufacturing devices using flexible carrier sheets with device substrates attached to the carrier sheet, storage/transport devices for the carrier sheet, and process tools capable of continuous processing of the carrier sheets.

Abstract: The present invention provides a method detecting metal silicide defects in a microelectronic device. The method comprises positioning (110) a portion of a semiconductor substrate in a field of view of an inspection tool. The method also comprises producing (120) a voltage contrast image of the portion, wherein the image is obtained using a collection field that is stronger than an incident field. The method further comprises using (130) the voltage contrast image to determine a metal silicide defect in a microelectronic device. Other aspects of the present invention include an inspection system (200) for detecting metal silicide defects and a method of manufacturing an integrated circuit (300).

Abstract: A method of forming single or dual damascene interconnect structures using either a via-first or trench first approach includes the steps of providing a substrate surface having an etch-stop layer thereon, a low-k dielectric layer on the etch-stop layer, and a dielectric capping layer on the low-k dielectric layer. In the single damascene process using trench pattern, a trench is etched through the capping layer, the low-k dielectric layer and the etch-stop layer to reach the substrate surface. In the via-first process, using a via pattern, the via is etched through the capping layer, the low-k dielectric layer and the etch-stop layer to reach the substrate surface. In the trench first process, using the via pattern the via is etched through the capping layer, the low-k dielectric layer and the etch-stop layer to reach the substrate surface.

Abstract: The present teachings provide methods for detection of metal silicide defects in a microelectronic device. In an exemplary embodiment, a portion of a semiconductor substrate may be positioned in a field of view of an inspection tool. The method also includes producing (120) a voltage contrast image of the portion, wherein the image is obtained using a collection field that is stronger than an incident field. The method also includes using (130) the voltage contrast image to determine a metal silicide defect in a microelectronic device. Other embodiments include an inspection system (200) for detecting metal silicide defects and a method of manufacturing an integrated circuit (300).

Abstract: The present invention provides a system for removing organic contaminants (216) from a copper seed layer that has been deposited on a semiconductor substrate (206). The present invention provides a housing (204) to enclose the semiconductor substrate within. An ultraviolet radiation source (210) is disposed within the housing. A treatment medium (208) is also provided within the housing. The semiconductor substrate is enclosed within the housing and exposed to the treatment medium. The ultraviolet radiation source exposes the semiconductor substrate to ultraviolet radiation, desorbing the contaminants from the seed layer.

Abstract: Methods (102) are presented for protecting copper structures (26) from corrosion in the fabrication of semiconductor devices (2), wherein a thin semiconductor or copper-semiconductor alloy corrosion protection layer (30) is formed on an exposed surface (26a) of a copper structure (26) prior to performance of metrology operations (206), so as to inhibit corrosion of the copper structure (26). All or a portion of the corrosion protection layer (30) is then removed (214) in forming an opening in an overlying dielectric (44) in a subsequent interconnect layer.

Abstract: A method of detecting interconnect defects in a semiconductor device. The method comprises positioning a portion of a semiconductor substrate, having a plurality of interconnects, in a field of view of an inspection tool. A voltage contrast image of the portion is produced. The voltage contrast image is obtained using a collection field that is at least about 1 percent different than an incident field. The method further comprises using the voltage contrast image to determine defective ones of the interconnects.

Abstract: The invention provides a method of fabricating a semiconductive device [200]. In this embodiment, the method comprises depositing a hydrocarbon layer [294] over a semiconductive substrate, forming an interconnect structure [295, 297] within the hydrocarbon layer [294], and removing the hydrocarbon layer [294] by sublimation.

Abstract: Semiconductor devices formed on wafers are inspected using a master wafer. A subject wafer of a semiconductor design is provided. The subject wafer has dies wherein semiconductor devices of the semiconductor design are formed and at a stage of fabrication. A current layer of the subject wafer is scanned to obtain a scanned layer/image. A master wafer comprising individual wafer/layer maps is obtained. The scanned layer is compared with a corresponding layer map. Matching and non-matching defects are identified from repetitive defects within the corresponding layer map and defects within the scanned layer. The matching defects are reviewed to classify and or identify causality. The master wafer is then updated.

Abstract: The present invention defines a system (100) for detecting copper contamination within a semiconductor manufacturing process. According to the present invention, a semiconductor wafer (102) is transferred (108) from a semiconductor manufacturing component (104), which may have exposed the wafer to copper contamination, to a measurement system (106). The measurement system measures an electrical value at a plurality of locations along a surface of the wafer, prior to and after exposure of the surface to an activation system (112). The activation system is provided to cause any copper contamination along the surface to form a precipitate thereon. An analysis component (110) is provided to receive electrical value and location information from the measurement system and to identify, from the measurements, the presence and location of copper contamination along the semiconductor wafer surface.

Abstract: Semiconductor devices formed on wafers are inspected using a master wafer. A subject wafer of a semiconductor design is provided. The subject wafer has dies wherein semiconductor devices of the semiconductor design are formed and at a stage of fabrication. A current layer of the subject wafer is scanned to obtain a scanned layer/image. A master wafer comprising individual wafer/layer maps is obtained. The scanned layer is compared with a corresponding layer map. Matching and non-matching defects are identified from repetitive defects within the corresponding layer map and defects within the scanned layer. The matching defects are reviewed to classify and or identify causality. The master wafer is then updated.

Abstract: The present invention provides an electroplating process and a method for manufacturing an integrated circuit. The electroplating process includes, among other steps, placing a substrate 290 in an enclosure 200 being substantially devoid of unwanted contaminants and forming a material layer 310 over the substrate 290 within the enclosure 200, the enclosure 200 still being substantially devoid of the unwanted contaminants. The electroplating process further includes forming a thin layer of oxide 410 over the material layer 310 within the enclosure 200, the enclosure 200 still being substantially devoid of the unwanted contaminants during the forming the thin layer of oxide 410.