Abstract: A strong interface is formed between an interconnect and an encapsulating layer to prevent the lateral drift of material from the interconnect along the bottom of the encapsulating layer. Diffusion barrier material is deposited on the top surface of the interconnect using a selective deposition process. The diffusion barrier material may be epitaxially grown from the interconnect during the selective deposition of the diffusion barrier material on the top surface of the interconnect to promote adhesion of the diffusion barrier material to the interconnect. An encapsulating layer is deposited on top of the diffusion barrier material. The diffusion barrier material and the encapsulating layer are comprised of a similar chemical element to promote adhesion of the diffusion barrier material to the encapsulating layer. The diffusion barrier material on the top surface of the interconnect prevents lateral drift of material comprising the interconnect along the encapsulating layer.

Abstract: Improved dielectric layers are formed by surface treating the dielectric layer with a silane plasma prior to forming a subsequent layer thereon. Embodiments include forming a trench in a low k dielectric layer and modifying the side surfaces of the trench by subjecting the dielectric to a silane plasma produced in a PECVD chamber. A conductive feature is formed by depositing a conformal barrier layer on the low k dielectric including the treated side surfaces of the dielectric and depositing a conductive layer within the trench.

Abstract: This invention describes improved apparatus and methods for spin-on deposition of semiconductor thin films. The improved apparatus provides for controlled temperature, pressure and gas compositions within the deposition chamber. The improved methods comprise dispensing of solutions containing thin film precursor via a moveable dispensing device and the careful regulation of the pattern of deposition of the precursor solution onto the wafer. The invention also comprises the careful regulation of deposition variables including dispensation time, wafer rpm, stop time and rates of wafer rotation. In one embodiment, the precursor solution is dispensed from the outer edge of the wafer toward the center. In alternative embodiments, processors regulate the movement of the dispensing arm and the precursor pump to provide an evenly dispensed layer of precursor solution. The invention also describes improved methods for evaporating solvents and curing thin films.

Abstract: Strong adhesion to doped low-k inter-layer dielectrics is provided by varying the composition of dopant near the surface layers of the inter-layer dielectric. The concentration of dopant is gradually increased from about zero atomic % at the interface between the inter-layer dielectric and semiconductor substrate to improve adhesion of the inter-layer dielectric to the semiconductor substrate. The concentration of dopant at the upper surface of the inter-layer dielectric is gradually decreased to about zero atomic % at the upper surface of the inter-layer dielectric film in order to improve adhesion of additional layers to the inter-layer dielectric.

Abstract: A method of forming a metal or metal nitride layer interface between a copper layer and a silicon nitride layer can include providing a metal organic gas or metal/metal nitride precursor over a copper layer, forming a metal or metal nitride layer from reactions between the metal organic gas or metal/metal nitride precursor and the copper layer, and depositing a silicon nitride layer over the metal or metal nitride layer and copper layer. The metal or metal nitride layer can provide a better interface adhesion between the silicon nitride layer and the copper layer. The metal layer can improve the interface between the copper layer and the silicon nitride layer, improving electromigration reliability and, thus, integrated circuit device performance.

Abstract: The degradation of deposited low dielectric constant interlayer dielectrics and gap fill layers, such as HSQ layers, during formation of contacts/vias is significantly reduced or prevented by employing a water vapor plasma to remove the photoresist mask. The use of a water vapor also enables rapid photoresist stripping at a rate of about 10 to about 20 KÅ/min. Embodiments include photoresist stripping with a water vapor plasma to prevent reduction of the number of Si—H bonds of an as-deposited HSQ layer below about 70%.

Abstract: A method of eliminating voids in the interlayer dielectric material of 0.18-&mgr;m flash memory semiconductor devices and a semiconductor device formed by the method. The present invention provides a method for eliminating voids in the interlayer dielectric of a 0.18-&mgr;m flash memory semiconductor device by providing a first BPTEOS layer, using a very low deposition rate and having a thickness in a range of approximately 3 kÅ; and providing a second BPTEOS layer, using a standard deposition rate and having a thickness in a range of approximately 13 kÅ, wherein both layers have an atomic dopant concentration of approximately 4.5% B and approximately 5% P. This two-step deposition process completely eliminates voids in the ILD for a 0.5-&mgr;m distance (gate-to-gate) as well as 0.38-&mgr;m distance (gate-to-gate) which is the future flash technology.

Abstract: A process for manufacturing a semiconductor device includes forming a first metallization level, forming a first etch stop layer, forming a low-k dielectric layer, forming a cap layer, depositing a resist, forming an opening; removing the resist, curing the dielectric material, etching the first etch stop layer, and filing the opening with metal. The first etch stop layer is formed over the first metallization level, and the low-k dielectric layer material is formed over the first etch stop layer. The cap layer is formed over the low-k dielectric layer material, and the resist is formed over the dielectric layer. Etching is used to form the opening. The resist is removed with an O2 stripping process. Curing of the dielectric material forms a dielectric layer and occurs after the resist is removed.

Abstract: In a first aspect of the present invention, a semiconductor device is disclosed. The semiconductor device comprises at least two gate stacks, each gate stack having two sides and oxide spacers on each of the two sides of each of the at least two gate stacks, wherein at least one of the oxide spacers is triangular shaped. In a second aspect of the present invention, a method and system for processing a semiconductor device is disclosed. The method and system for processing a semiconductor comprise forming at least two gate stacks over a semiconductor substrate, depositing an oxide layer over the at least two gate stacks, and etching the oxide layer to form at least one oxide spacer in between the at least two gate stacks, wherein the at least one oxide spacer is triangular shape. Through the use the present invention, the voids that are created in the semiconductor device during conventional semiconductor processing are eliminated.

Abstract: A method and system for providing a plurality of contacts in a flash memory device is disclosed. The flash memory device includes a plurality of gate stacks and a plurality of field insulating regions adjacent to a portion of the plurality of gate stacks. The method and system include providing an etch stop layer covering the plurality of field insulating regions. The etch stop layer has an etch selectivity different from a field insulating region etch selectivity of the plurality of field insulating regions. The method and system also include providing an insulating layer covering the plurality of gate stacks, the plurality of field insulating regions and the etch stop layer. The method and system further include etching the insulating layer to provide a plurality of contact holes. The insulating layer etching step uses the etch stop layer to ensure that the insulating etching step does not etch through the plurality of field insulating regions.

Abstract: An ultra-large scale integrated circuit is manufactured by using silicon-based, low dielectric constant materials in which the dielectric constant has been reduced by spinning on the dielectric to silicon wafers, eliminating soft bake steps, and heating the wafers to about 400° C. for about one hour in a vacuum or inert atmosphere.

Abstract: A method of forming a damascene structure in a semiconductor device arrangement uses a low k dielectric material in an etch stop layer that overlays a metal interconnect layer. The etch stop layer protects the metal interconnect layer, made of copper, for example, during the etching of a dielectric layer that overlays the etch stop layer. Following the etching of the dielectric layer, which stops on the etch stop layer, the etch stop layer is then etched with a chemistry that does not damage the underlying copper in the metal interconnect layer. The lower dielectric constant material employed in the etch stop layer reduces the overall dielectric constant of the film, thereby improving the operating performance of the chip.

Abstract: The present invention is a method and system for eliminating voids in a semiconductor device. The method comprises the steps of forming metal lines over a semiconductor substrate, forming a first oxide layer utilizing a high density plasma deposition technique, forming a second oxide layer utilizing a carbon free resin and forming a topside dielectric layer. Through the use of a method in accordance with the present invention, the voids that are created in the dielectric films during conventional semiconductor processing methodology are eliminated. The use of a high density plasma deposition technique provides a more directional deposition that can get between metal lines that are separated by smaller gaps. The dielectric films are thereby strengthened, which increases the reliability of the semiconductor device.

Abstract: This invention describes improved apparatus and methods for spin-on deposition of semiconductor thin films. The improved apparatus provides for controlled temperature, pressure and gas compositions within the deposition chamber. The improved methods comprise dispensing of solutions containing thin film precursor via a moveable dispensing device and the careful regulation of the pattern of deposition of the precursor solution onto the wafer. The invention also comprises the careful regulation of deposition variables including dispensation time, wafer rpm, stop time and rates of wafer rotation. In one embodiment, the precursor solution is dispensed from the outer edge of the wafer toward the center. In alternative embodiments, processors regulate the movement of the dispensing arm and the precursor pump to provide an evenly dispensed layer of precursor solution. The invention also describes improved methods for evaporating solvents and curing thin films.

Abstract: An ultra-large scale integrated circuit is manufactured by using silicon-based, low dielectric constant materials which are spin-coated, dried, cured, and capped in-situ in chemical vapor deposition equipment. The low dielectric constant material is spun on, processed in chemical vapor deposition equipment, subject to chemical-mechanical polishing, and then processed by a conventional photolithographic process for depositing conductors. The material is then reprocessed for each successive layer of conductor separated by dielectric.

Abstract: This invention describes improved apparatus and methods for spin-on deposition of thin films applicable to the manufacture of semiconductor devices. The improved apparatus provides for controlled temperature, pressure and gas compositions within the deposition chamber. The improved methods comprise dispensing of solutions containing thin film precursor via a moveable dispensing device and the careful regulation of the pattern of deposition of the precursor solution onto the wafer. The invention also comprises the careful regulation of deposition variables including dispensation time, wafer rpm, stop time and rates of wafer rotation. In one embodiment, the precursor solution is dispensed from the outer edge of the wafer toward the center. In alternative embodiments, processors regulate the movement of the dispensing arm and the precursor pump to provide an evenly dispensed layer of precursor solution. The invention also describes improved methods for evaporating solvents and curing thin films.

Abstract: The adhesion of a barrier or capping layer to a Cu or Cu alloy interconnect member is significantly enhanced by treating the exposed surface of the Cu or Cu alloy interconnect member, after CMP, in a reaction chamber with a plasma containing ammonia and nitrogen for a brief period of time to reduce the surface oxide and then introducing silane into the reaction chamber to deposit the barrier layer, e.g., silicon nitride, under high density plasma conditions in the presence of nitrogen. The presence of nitrogen during plasma oxide layer reduction and plasma barrier layer deposition significantly improves adhesion of the barrier layer to the Cu or Cu alloy surface.

Abstract: The present invention provides a method for reducing the gate aspect ratio of a flash memory device. The method includes forming a tunnel oxide layer on a substrate; forming a polysilicon layer on the tunnel oxide layer; forming an insulating layer on the polysilicon layer; forming a control gate layer on the polysilicon layer; etching at least the tunnel oxide layer, the insulating layer, and the control gate layer to form at least two stack structures; forming a plurality of spacers at sides of the at least two stack structures; and filling at least one gap between the at least two stack structures with an oxide, where the control gate layer provides a gate aspect ratio which allows for a maximum step coverage by the oxide. In a preferred embodiment, the method uses nickel silicide instead of the conventional tungsten silicide in the control gate layers of the cells of the device.

Abstract: A transmission electron microscopy (TEM) or scanning electron microscopy (SEM) sample preparation method includes the steps of depositing a metal layer on top of a substrate, depositing a silicon nitride passivation layer on top of the metal layer, and cutting the substrate and the metal and passivation layers to expose their cross-sections for examination by electron microscopy. As a result, a TEM/SEM sample having sharp, well-defined boundaries is produced.

Abstract: Improved methods for manufacturing semiconductor devices incorporating barrier layers at metal/dielectric interfaces include the use of nitrogen-rich plasma, ion beam implantation and/or electromagnetic radiation to form regions of nitrided metal. The barrier layers decrease the diffusion of dopants such as fluorine, phosphorous and boron from the dielectric material into the metal, thereby decreasing the formation of metal salts. By decreasing the formation of metal salts, the barrier layers of this invention decrease the formation of voids and areas of delamination, and thereby decrease the loss of electrical reliability during manufacture and during use. Additional aspects of this invention include methods for monitoring the deposition of thin metal films using sheet resistance measurements, and further embodiments of this invention include methods for monitoring the surface texture of films that undergo phase transitions.