Abstract: A method is provided for manufacturing a semiconductor with fewer steps and minimized variation in the etching process by using SiON as a bottom antireflective (BARC) layer and hard mask in conjunction with a thin photoresist layer. In one embodiment, an etch-stop layer is deposited on a semiconductor substrate, a dielectric layer is deposited on top of the etch-stop layer, and a BARC is deposited on top of the dielectric layer. The BARC is deposited by PECVD to enrich the BARC with semiconductor material to increase the extinction coefficient of the BARC so its thickness can be reduced. A photoresist layer with a thickness less than the thickness of the BARC is then deposited on top of the BARC. The photoresist is then patterned, photolithographically processed, developed, and removed. The BARC is then etched away in the pattern developed on the photoresist and the photoresist is then removed. The BARC is then used as a mask for the etching of the dielectric layer.

Abstract: The present invention provides a method for selectively removing anti-reflective coating (ARC) from the surface of an dielectric layer over the surface of a substrate without scratching the dielectric layer and/or tungsten contacts formed therein. In one embodiment, a fluoromethane (CH3F)/oxygen (O2) etch chemistry is used to selectively remove the ARC layer without scratching and/or degradation of the dielectric layer, source/drain regions formed over the substrate, and a silicide layer formed atop stacked gate structures. The CH3F/O2 etch chemistry etches the ARC layer at a rate which is significantly faster than the etch rates of the dielectric layer, the source/drain regions and the silicide layer. In addition, by removing the ARC layer prior to the formation of tungsten contacts by filling of contact openings formed in the dielectric layer with tungsten, potential scratching of tungsten contacts due to ARC layer removal is eliminated.

Abstract: In the manufacture of sub 0.35 micron semiconductors using deep ultraviolet lithography, a bilayer of silicon dioxide on top of silicon oxynitride is used as bottom anti-reflective coating and an etch hard mask for photolithographic resist. Since the silicon dioxide is optically transparent at the deep ultraviolet wavelengths being used (248 nm), its thickness in combination with a preselected reflective silicon oxynitride thickness satisfies the zero reflectivity goal and, at the same time, is adequately thick to serve as a hard mask for self-aligned etch and self-aligned-source etch.

Abstract: In a method for forming an interlayer dielectric (ILD) coating on microcircuit interconnect lines of a substrate, a SiON layer is formed by using plasma-enhanced chemical vapor deposition. The deposition using a plasma formed of nitrogen, nitrous oxide, and silane gases, with the gases being dispensed at regulated flow rates and being energized by a radio frequency power source. The plasma reacts to form SiON which is deposited on a semiconductor substrate. During processing the deposition temperature is reduced to under 400 degrees Celsius, specifically temperatures in the range of about 350 degrees Celsius to about 380 degrees, Celsius, resulting in a substantially reduced incidence of stress-induced voiding in the underlying interconnect lines. Additionally, during deposition, minor adjustments are made to deposition temperature and process pressure to control the optical characteristics of the SiON layer.

Abstract: In a photo-lithographic step for providing contact points to lower layers of a semiconductor device, an anti-reflective coating (ARC) layer, such as FLARE 2.0™, is used to provide a good contact points to an underlayer. After the contact points are made, the anti-reflective coating layer is removed, with the removal being performed in a same step in which a photo-resist is removed from the semiconductor device. In an alternative configuration, the ARC layer remains in the semiconductor device after the fabrication process is competed, thereby acting as an interlayer dielectric during operation of the semiconductor device.

Abstract: In a method for forming an interlayer dielectric (ILD) coating on microcircuit interconnect lines of a substrate, a SiON layer is formed by using plasma-enhanced chemical vapor deposition. The deposition using a plasma formed of nitrogen, nitrous oxide, and silane gases, with the gases being dispensed at regulated flow rates and being energized by a radio frequency power source. The plasma reacts to form SiON which is deposited on a semiconductor substrate. During deposition, silane flow rates are regulating and reducing to less than sixty standard cubic centimeters per minute, thereby reducing the incidence of stress-induced voiding in the underlying interconnect lines. During deposition adjustments are made in deposition temperature and process pressure to control the characteristics of the SiON layer. The SiON layer is tested for acceptable optical properties and acceptable SiON layers are coated with a SiO2 layer to complete formation of the ILD.

Abstract: In a method for forming an interlayer dielectric (ILD) coating on microcircuit interconnect lines of a substrate, the substrate and interconnect lines are annealed prior to deposition of an ILD. A post annealing SiON layer is formed by using plasma-enhanced chemical vapor deposition. The deposition using a plasma formed of nitrogen, nitrous oxide, and silane gases, with the gases being dispensed at regulated flow rates and being energized by a radio frequency power source. The plasma reacts to form SiON which is deposited on a semiconductor substrate. Additionally, during deposition, minor adjustments are made to deposition temperature and process pressure to control the optical characteristics of the SiON layer. The SiON layer is tested for acceptable optical properties and acceptable SiON layers are coated with a SiO2 layer to complete formation of the ILD. Once the ILD is formed the substrate is in readiness for further processing.

Abstract: In one embodiment, the present invention relates to a method of depositing a dielectric layer over a stacked interconnect structure, involving the steps of: providing a substrate having at least one stacked interconnect structure comprising at least one of an aluminum layer and an aluminum alloy layer; depositing the dielectric layer over the stacked interconnect structureunder a pressure from about 1 mTorr to about 6 mTorr, an O.sub.2 flow rate from about 110 sccm to about 130 sccm and a silane flow rate from about 52 sccm to about 60 sccm at a bias power from about 2500 W to about 3100 W,under a pressure from about 2 Torr to about 2.8 Torr, an N.sub.2 flow rate from about 7 l to about 11.5 l, an N.sub.2 O flow rate from about 1 l to about 2 l and a silane flow rate from about 250 sccm to about 300 sccm at a power from about 900 W to about 1300 W at a temperature from about 300.degree. C. to about 350.degree. C., orunder a pressure from about 2 Torr to about 2.8 Torr, an N.sub.

Abstract: The present invention provides a method for selectively removing anti-reflective coating (ARC) from the surface of a dielectric layer over the surface of a substrate without scratching the dielectric layer and/or tungsten contacts formed therein. In one embodiment, a fluoromethane (CH.sub.3 F)/oxygen (O.sub.2) etch chemistry is used to selectively remove the ARC layer. The CH.sub.3 F/O.sub.2 etch chemistry etches the ARC layer at a rate which is significantly faster than the etch rates of the dielectric layer or the tungsten contacts.

Abstract: In a photo-lithographic step for providing contact points to lower layers of a semiconductor device, an anti-reflective coating (ARC) layer, such as FLARE 2.0.TM., is used to provide a good contact points to an underlayer. After the contact points are made, the anti-reflective coating layer is removed, with the removal being performed in a same step in which a photo-resist is removed from the semiconductor device. In an alternative configuration, the ARC layer remains in the semiconductor device after the fabrication process is competed, thereby acting as an interlayer dielectric during operation of the semiconductor device.