Abstract: A semiconductor device and method having a low-permittivity material between closely-spaced leads in order to decrease unwanted capacitance, while having a more structurally strong dielectric between widely-spaced leads where capacitance is not as critical. A metal layer 14 is deposited on a substrate 12 of a semiconductor wafer 10, where the metal layer 14 has a first region 15 and a second region 17. An insulating layer 39 is deposited on the metal layer, and the insulating layer 39 is patterned with a conductor pattern of widely-spaced leads and closely-spaced leads. Widely-spaced leads 16 are formed in the first region 15 of the metal layer 14. At least adjacent portions of closely-spaced leads 18 are formed in the second region 17 of the metal layer 14. A low-permittivity material 34 is deposited between adjacent portions of the closely-spaced leads 18. A structural dielectric layer 26 is deposited between at least the widely-spaced leads.

Abstract: A semiconductor device and method having a low-permittivity material between closely-spaced leads in order to decrease unwanted capacitance, while having a more structurally strong dielectric between widely-spaced leads where capacitance is not as critical. A metal layer 14 is deposited on a substrate 12 of a semiconductor wafer 10, where the metal layer 14 has a first region 15 and a second region 17. An insulating layer 39 is deposited on the metal layer, and the insulating layer 39 is patterned with a conductor pattern of widely-spaced leads and closely-spaced leads. Widely-spaced leads 16 are formed in the first region 15 of the metal layer 14. At least adjacent portions of closely-spaced leads 18 are formed in the second region 17 of the metal layer 14. A low-permittivity material 34 is deposited between adjacent portions of the closely-spaced leads 18. A structural dielectric layer 26 is deposited between at least the widely-spaced leads.

Abstract: A semiconductor device and method having a low-permittivity material between closely-spaced leads in order to decrease unwanted capacitance, while having a more structurally strong dielectric between widely-spaced leads where capacitance is not as critical. Metal layer 14 is deposited on a substrate 12 of a semiconductor wafer 10, where the metal layer 14 has a first portion 15 and a second portion 17. Widely-spaced leads 16 are formed in the first portion 15 of the metal layer 14, and a first structural dielectric layer 26 is deposited on at least the widely-spaced leads. Closely-spaced leads 18 are formed in the second portion 17 of the metal layer 14, and low-permittivity material 34 is deposited between closely-spaced leads 18. A second structural dielectric layer 36 is deposited on at least low-permittivity material 34 and closely-spaced leads 18.

Abstract: This invention provides a semiconductor device and process for making the same with dramatically reduced capacitance between adjacent conductors and an interlayer dielectric construction which emphasizes mechanical strength, etch compatibility, and good heat transfer. This process can include applying a solution between conductors 24, and then gelling, surface modifying, and drying the solution to form an extremely porous dielectric layer 28. A non-porous dielectric layer 30 may be formed over porous layer 28, which may complete an interlayer dielectric and provide mechanical strength, heat transfer, and a solid layer for via etch. A novel process for creating the porous dielectric layer is disclosed, which can be completed at vacuum or ambient pressures, yet results in porosity, pore size, and shrinkage of the dielectric during drying comparable to that previously attainable only by drying gels at supercritical pressure.

Abstract: A semiconductor device and method having a low-permittivity material between closely-spaced leads in order to decrease unwanted capacitance, while having a more structurally strong dielectric between widely-spaced leads where capacitance is not as critical. Metal layer 14 is deposited on a substrate 12 of a semiconductor wafer 10, where the metal layer 14 has a first portion 15 and a second portion 17. Widely-spaced leads 16 are formed in the first portion 15 of the metal layer 14, and a first structural dielectric layer 26 is deposited on at least the widely-spaced leads. Closely-spaced leads 18 are formed in the second portion 17 of the metal layer 14, and low-permittivity material 34 is deposited between closely-spaced leads 18. A second structural dielectric layer 36 is deposited on at least low-permittivity material 34 and closely-spaced leads 18.

Abstract: A semiconductor device with air gaps 22 between metal leads 16, comprising metal leads 16 formed on a substrate 12, air gaps 22 between metal leads 16, a 10-50% porous dielectric layer 20 on the metal leads 16 and over the air gaps 22, and a non-porous dielectric layer 24 on the porous dielectric layer 20. Optional features include a patterned oxide 28 over the metal leads 16 and a passivation layer 26 over the metal leads 16 and patterned oxide 28. The porous dielectric layer 20 may comprise an aerogel or xerogel.

Abstract: A diffusion barrier trilayer 42 is comprised of a bottom layer 44, a seed layer 46 and a top layer 48. The diffusion barrier trilayer 42 prevents reaction of metallization layer 26 with the top layer 48 upon heat treatment, resulting in improved sheet resistance and device speed.

Abstract: A semiconductor device and process for making the same are disclosed which use porous dielectric materials to reduce capacitance between conductors, while allowing conventional photolithography and metal techniques and materials to be used in fabrication. In one structure, patterned conductors 18 are provided on an interlayer dielectric 10, with a substrate encapsulation layer 31 deposited conformally over this structure. A layer of porous dielectric material 22 (e.g. dried SiO.sub.2 gel) is then deposited to substantially fill the gaps between and also cover the conductors. A substantially solid cap layer 14 of a material such as SiO.sub.2 is then deposited, followed by a photolithography step to define via locations. Vias are etched through the cap layer, and then through the porous dielectric.

Abstract: A method for minimizing reaction between metal conductors and other metals to minimize change in sheet resistance of the conductors upon heat treatment which includes providing a substrate. The substrate is preferably one of a dielectric, a metal or a semiconductor. A metallic diffusion barrier layer, preferably one of TiN, TiW or TiWN and preferably having a thickness of from about 10 nanometers to about 100 nanometers, is deposited on the substrate, preferably by one of sputtering, electron beam evaporation or chemical vapor deposition. The exposed surface of the metallic diffusion barrier layer is treated with a plasma, preferably an oxygen plasma, a nitrous oxide plasma or a plasma of an oxygen-containing species. An electrical conductor, preferably one of aluminum, aluminum-metal alloys, copper or copper-metal alloys and preferably having a thickness of from about 100 nanometers to about 1200 nanometers, is then deposited on the plasma-treated surface of the metallic diffusion barrier layer.

Abstract: A semiconductor device and process for making the same which reduces capacitance between adjacent conductors on a connection layer, reduces overetching due to via misalignment or uneven device topography, and maintains a rigid structure with good heat transfer characterisitics. In one embodiment, horizontal gaps between the patterned conductors 18 and 44 are substantially filled with an organic-containing dielectric material (Allied Signal 500 Series, for example) 22 and 54. Inorganic dielectric layers 24 and 56 are formed over organic-containing dielectric layers 22 and 54, respectively, from a material such as silicon dioxide. Vias are etched through the inorganic dielectric layers using an etch process such as fluorocarbons in a high density plasma which does not appreciably etch the organic-containing dielectric material.

Abstract: This invention provides a semiconductor device and process for making the same with dramatically reduced capacitance between adjacent conductors and an interlayer dielectric construction which emphasizes mechanical strength, etch compatibility, and good heat transfer. This process can include applying a solution between conductors 24, and then gelling, surface modifying, and drying the solution to form an extremely porous dielectric layer 28. A non-porous dielectric layer 30 may be formed over porous layer 28, which may complete an interlayer dielectric and provide mechanical strength, heat transfer, and a solid layer for via etch. A novel process for creating the porous dielectric layer is disclosed, which can be completed at vacuum or ambient pressures, yet results in porosity, pore size, and shrinkage of the dielectric during drying comparable to that previously attainable only by drying gels at supercritical pressure.

Abstract: A semiconductor device and process for making the same are disclosed which incorporate organic dielectric materials to form self-aligned contacts (SACTs) reliably, even in deep, narrow gaps. In one embodiment, conductors 26 with insulating conductor caps 28 are formed over a silicon substrate 20 with a thin gate oxide 22. A conformal dielectric layer 30, preferably of thermally-grown oxide, is deposited over this structure, which is then covered with an organic-containing layer 32 and an inorganic cap layer 34 (e.g., CVD TEOS). An etch window 38 is patterned in photoresist layer 36 and used as a mask to etch cap window 39 through layer 34, using layer 32 as an etch stop. A second etch removes organic-containing layer 32 in contact window 41 (and preferably strips photoresist), using conformal layer 30 as an etch stop. A short anisotropic etch may be used to clear conformal layer 30 from gap bottom 43, after which conducting material 40 may be used to make electrical contact to the substrate.

Abstract: A semiconductor device and process for making the same are disclosed which use porous dielectric materials to reduce capacitance between conductors, while allowing conventional photolithography and metal techniques and materials to be used in fabrication. In one structure, patterned conductors 18 are provided on an interlayer dielectric 10, with a substrate encapsulation layer 32 deposited conformally over this structure. A layer of porous dielectric material 22 (e.g. dried SiO.sub.2 gel) is then deposited to substantially fill the gaps between and also cover the conductors. A substantially solid cap layer 24 of a material such as SiO.sub.2 is then deposited, followed by a photolithography step to define via locations. Vias are etched through the cap layer, and then through the porous dielectric.

Abstract: A method of fabricating a transistor on a wafer including: forming a doped transistor body 42 on top of an insulator 34; doping source/drain regions in the transistor body; forming a gate oxide 44 on top of the transistor body; forming sidewall spacers along the transistor body; depositing a metal layer over the transistor body; forming an amorphous silicon layer over the metal layer, the amorphous silicon layer patterned in a gate and a local interconnect configuration; annealing to form silicided regions above the source/drain regions within the transistor body, and where the metal layer reacts with the amorphous silicon layer to create a silicided gate 50 and a silicided local interconnect 50; and etching unsilicided portions of the metal layer to leave silicided source/drain regions, a silicided gate, and a silicided local interconnect.

Abstract: An integrated circuit device including at least one polysilicon resistor 10 is disclosed herein. A polysilicon layer 24 is formed, possibly over a field oxide 12. The polysilicon layer 24 is then doped to achieve a selected sheet resistance. An insulating layer 18 (e.g., an oxide, a nitride, or a combination thereof) is then formed over the polysilicon layer 24. The insulating layer 18 is patterned and etched to define a resistor body 14 in the underlying polysilicon layer 24. The polysilicon layer 24 is then patterned and etched to define first and second resistor heads 16 abutting the resistor body 14 while simultaneously at least one polysilicon element 28 of a second electronic device is formed. Other systems and methods are also disclosed.

Abstract: A method for forming air gaps 22 between metal leads 16 of a semiconductor device and semiconductor device for same. A metal layer is deposited on a substrate 12. The metal layer is etched to form metal leads 16. A disposable solid layer 18 is deposited between the metal leads 16. A porous dielectric layer 20 is deposited on the disposable solid layer 18 and the tops of the leads 16, and the disposable solid layer 18 is removed through the porous dielectric layer 20, to form air gaps 22 between the metal leads 16 beneath the porous dielectric layer 20. The air gaps have a low-dielectric constant and result in reduced sidewall capacitance of the metal leads.

Abstract: A method for fabricating an integrated circuit having a buried doped region is disclosed. A thermal oxide layer is formed over a portion of a p-type substrate at which an n+ buried doped region is not to be formed, masking the implant for the buried doped region. Anneal of the implant is performed in an oxidizing atmosphere, growing further oxide over the surface. The oxide layers are removed, and a p-type blanket implant is performed for isolation purposes and, if desired, to form a p-type buried doped region; the doping concentration of the n+ buried doped region retards diffusion of the boron to the surface thereover. Alternatively, a higher than normal doping level in the substrate can provide sufficient boron for isolation.

Abstract: A method of fabricating a transistor on a wafer including; forming a doped transistor body 42 on top of an insulator 34; doping source/drain regions in the transistor body; forming a gate oxide 44 on top of the transistor body; forming sidewall spacers along the transistor body; depositing a metal layer over the transistor body; forming an amorphous silicon layer over the metal layer, the amorphous silicon layer patterned in a gate and a local interconnect configuration; annealing to form silicided regions above the source/drain regions within the transistor body, and where the metal layer reacts with the amorphous silicon layer to create a silicided gate 50 and a silicided local interconnect 50; and etching unsilicided portions of the metal layer to leave silicided source/drain regions, a silicided gate, and a silicided local interconnect.

Abstract: A method for forming a refractory metal silicide on a semiconductor device is disclosed. The method comprises the steps of depositing a layer of refractory metal on the device and reacting the layer with nitrogen. The reaction is accomplished at a partial pressure of nitrogen greater than one atmosphere. The disclosed process allows thin layers of low resistance silicide to be formed for use as an ohmic contact while also forming a nitride layer for use as a device-to-device interconnection.

Abstract: A process and structure for resolving the divergent etching requirements of a relatively thick base oxide (62) and a relatively thin gate oxide (64) in a BiCMOS integrated circuit. The necessity of etching base oxide (62) is eliminated by extending nitride mask (58) over the extrinsic base region (86) so that the relatively thick base oxide (62) only covers intrinsic base region (60) and tab region (61). Base oxide (62) at tab region (61) is partially etched in the course of forming sidewall oxide filaments (78), resulting in the residual tab oxide (62'). An extrinsic base implant is performed in extrinsic base region (86) and tab region (61), with the presence of residual tab oxide (62') affecting the profile of the implant so that it is stepped. The resulting structure, after an anneal, is extrinsic base (87'), an intrinsic base (63) (formed prior to the extrinsic base implant), and an overlap region (88') common to both.