Integrated Circuit Structures, Semiconductor Structures, And Semiconductor Die
Methods for fabricating integrated circuit devices on an acceptor substrate devoid of circuitry are disclosed. Integrated circuit devices are formed by sequentially disposing one or more levels of semiconductor material on an acceptor substrate, and fabricating circuitry on each level of semiconductor material before disposition of a next-higher level. After encapsulation of the circuitry, the acceptor substrate is removed and semiconductor dice are singulated. Integrated circuit devices formed by the methods are also disclosed.
Latest Micron Technology, Inc. Patents:
- Microelectronic devices and electronic systems
- Arrays of memory cells including pairs of memory cells having respective charge storage nodes between respective access lines
- Stacked light emitting diode (led) hologram display
- Integrated transistors having gate material passing through a pillar of semiconductor material, and methods of forming integrated transistors
- Apparatus with memory process feedback
This patent resulted from a continuation application of U.S. patent application Ser. No. 13/471,048, filed May 14, 2012, entitled “Integrated Circuit Structures, Semiconductor Structures, And Semiconductor Die”, naming Gurtej S. Sandhu and Krishna Parrat as inventors, which is a divisional application of U.S. patent application Ser. No. 12/392,742, filed Feb. 25, 2009, now U.S. Pat. No. 8,198,172, entitled “Methods of Forming Integrated Circuits Using Donor And Acceptor Substrates”, naming Gurtej S. Sandhu and Krishna Parrat as inventors, the disclosures of which are incorporated by reference.
TECHNICAL FIELDThe present invention, in various embodiments, relates generally to methods for fabricating integrated circuit devices, such as memory, logic or application specific integrated circuits (ASICs) without consuming an acceptor semiconductor substrate on which the integrated circuit devices are formed. More specifically, embodiments of the invention include integrated circuit fabrication methods in which semiconductor material is provided for fabrication of integrated circuits at one or more levels over an acceptor substrate having no circuitry thereon. In addition, embodiments of the present invention comprise multi-level integrated circuits.
BACKGROUNDConventionally, three-dimensional (3D) integrated circuit (IC) devices have been fabricated to improve chip density, by initially forming individual circuit devices and subsequently stacking and bonding the chips together to form a multi-level chip stack or assembly. Consequently, the time, materials and process acts expended in carrying out individual chip fabrication, forming an assembly and electrically connecting the chips results in undesirably high cost. Moreover, stacking and electrical connection of the individually fabricated chips may lead to increased resistance and signal delay in the overall circuit due to undesirably long signal paths. Further, transmission of signals through wiring of one layer of the assembly may electrically interfere with wiring on other layers, e.g., cross-talk.
Another technique that has been suggested to increase chip density, for minimization of design dimension, is a so-called “bottom-up” approach. In this approach, circuits are fabricated conventionally on a base substrate, such as a silicon-on-insulator (SOI) wafer, followed by growth of successive layers of silicon on the wafer to provide an active surface and fabrication of additional circuit levels on each successive silicon layer prior to growth of the next-higher level. The process is repeated to create a device having a desired number of layers. One of the difficulties of this approach is that each circuit level, other than the last fabricated, is exposed to multiple thermal cycles as subsequent levels are formed. Further, due to the thermal cycling required by a bottom-up approach, suitable material choices for circuit structures are limited. Additionally, this approach requires an excessive amount of time as a consequence of growing each new layer of silicon on the base substrate.
Further, the foregoing approaches to multi-level circuit fabrication each require the use, and consumption, of a silicon wafer or other bulk substrate, which bulk substrate comprises a significant portion of the total cost of the fabrication process, on the order of twenty to thirty percent.
Accordingly, there are needs for processes to make 3D integrated circuits more efficiently and with reduced expense, while facilitating minimization of the overall dimensions of the device.
In the drawings, in which various features of embodiments of the present invention are depicted:
The illustrations presented herein are not meant to be actual views of any particular memory devices, logic devices, ASIC devices, or other semiconductor devices, but are merely idealized representations which are employed to describe the present invention in various embodiments. Further, the relative dimensions of some elements of the drawings, such as for example thicknesses of various materials, may be exaggerated for clarity. Additionally, elements common between figures may retain the same or similar numerical designation.
The present invention comprises embodiments of methods of fabricating integrated circuit devices on an acceptor substrate without consumption thereof, as well as resulting integrated circuit devices, which may comprise multiple levels of integrated circuitry sequentially fabricated on superposed levels of semiconductor foundation material. The term “three-dimensional integrated circuit” as used herein, means and includes a plurality of integrated circuits arranged in planes or levels disposed vertically, one above another. The terms “form” and “forming” as used herein, encompass both disposition of a material as a final material or components thereof, and in situ formation of a material. The term “another” as used herein, means and includes both a component or structure used a plurality of times, as well as an additional occurrence of fabrication of a type of component or structure.
An embodiment of a process for fabricating a multi-level integrated circuit according to the present invention is described. In
As shown in
As a non-limiting example, the foundation semiconductor material may be placed on acceptor substrate 100 by a process described herein using a modification of so-called SMART-CUT® technology. Such processes are described in detail in, for example, U.S. Pat. No. RE 39,484 to Bruel, U.S. Pat. No. 6,303,468 to Aspar et al., U.S. Pat. No. 6,335,258 to Aspar et al., U.S. Pat. No. 6,756,286 to Moriceau et al., U.S. Pat. No. 6,809,044 to Aspar et al., U.S. Pat. No. 6,946,365 to Aspar et al., and U.S. Patent Application Publication No. 2006/0099776 to Dupont. However, other processes suitable for fabricating a semiconductor material on the surface of acceptor substrate 100 may also be used, if sufficiently low processes temperatures are maintained. In conventional implementation of SMART-CUT® technology, donor and acceptor wafers are bonded together using a high temperature anneal, on the order of about 1000° C. to about 1300° C. Such temperatures are unacceptable for use when a substrate already bears circuitry fabricated thereon. For example, processing temperatures should not exceed about 800° C. when flash memory is fabricated. However, an additional plasma activation act may be integrated into a conventional SMART-CUT® technology fabrication process to lower a required substrate bonding temperature, as described in detail below.
In an embodiment, a plurality of ions of rare gases (e.g., neon, argon, krypton, or xenon), hydrogen, or helium may be implanted into the donor substrate 200 to form an implanted region 202. As represented by directional arrows 204, a conventional ion source (not shown) may be used to implant the plurality of ions into the donor substrate 200 in a direction substantially perpendicular to a major surface 206 of the donor substrate 200 to create the implanted region 202, which may also be characterized as a transfer region, the inner boundary 208 of which is shown in the donor substrate 200 in broken lines. As known in the art, the depth to which the ions are implanted into the donor substrate 200 is at least partially a function of the energy with which the ions are implanted. Generally, ions implanted with less energy will be implanted at relatively lesser depths, while ions implanted with higher energy will be implanted at relatively greater depths. The inner boundary 208 of implanted region 202 lies substantially parallel to the major surface 206 of the donor substrate 200 and is at a preselected depth which is dependent on selected parameters of the atomic species implant process, as is well known to one of ordinary skill in the art. As a non-limiting example, hydrogen ions may be implanted into the donor substrate with an energy selected to form the inner boundary 208 at a depth D of between about eighty nanometers (80 nm) and about five hundred nanometers (500 nm) (about 800 Å to about 5000 Å), and more particularly, of about two hundred nanometers (200 nm) (about 2000 Å) within the donor substrate 200.
The inner boundary 208 of implanted region 202 comprises a layer of microbubbles or microcavities (not shown) comprising the implanted ion species, and provides a weakened structure within donor substrate 200. The donor substrate 200 may then be thermally treated at a temperature above that at which ion implantation is effected, in accordance with the disclosures of the patent documents in the preceding paragraph, to effect crystalline rearrangement in the semiconductor material of the donor substrate 200 and coalescence of the microbubbles or microcavities.
An attachment surface 210 to be bonded to dielectric material 106 on acceptor substrate 100 (
As shown in
Donor substrate 200 may then have its new major surface 206n, which is substantially at the location of former inner boundary 208 of implanted region 202, smoothed as desired, ion-implanted and plasma-activated in preparation for transfer of another thickness of semiconductor material for use as a foundation material 212. It is contemplated that each donor substrate 200, if comprising a silicon wafer of conventional initial thickness, may be used to donate foundation material 212 at least about ten times, if about a 2000 Å thickness of silicon is transferred each time a layer of silicon is donated. It is further contemplated that, as thicknesses of semiconductor material are removed from the donor substrate 200, it may be desirable to bond a carrier to the back surface of donor substrate 200 to maintain mechanical integrity of the donor substrate 200 during handling, ion implantation, plasma activation, bonding to an acceptor substrate 100 and shearing of each transfer region therefrom.
Referring still to
As shown in
As shown in
The circuitry of 3D integrated circuit structure 300 may then be probe tested in a conventional manner from the top thereof and, as also depicted in
As also shown in
The 3D integrated circuit structure 300 with optional carrier substrate 400 bonded thereto may then be inverted, as depicted in
In a further embodiment depicted in
As depicted in
In another embodiment, each of the levels of foundation material 212, 212′ and 212″ may be stepped back from the next lowermost foundation material 212, as depicted in
Although the foregoing description includes many specifics, these are not limiting of the scope of the present invention but, merely, as providing illustrations of some of embodiments. Similarly, other embodiments of the invention may be devised which are encompassed by the scope of the invention. Features from different embodiments may be employed in combination. The scope of the invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. All additions, deletions, and modifications to the invention as disclosed herein which fall within the meaning and scope of the claims are to be embraced thereby.
CONCLUSIONEmbodiments of the present invention comprise methods of circuit fabrication on an acceptor substrate having no circuitry thereon. One or more levels of circuitry may be respectively and sequentially formed on levels of foundation material severed from a donor substrate after bonding to the acceptor substrate. After a desired number of levels of circuitry are formed, the resulting integrated circuit, encapsulated in a passivation material, is removed from the acceptor substrate. To effect the removal, a sacrificial material interposed between the circuitry and the acceptor substrate may be removed, as by etching with an etchant selective to the sacrificial material over the circuitry encapsulant and the acceptor substrate.
Embodiments of the invention comprise 3D integrated circuits, which may be singulated into individual semiconductor dice.
Claims
1-24. (canceled)
25. An integrated circuit structure, comprising:
- a plurality of superimposed levels of integrated circuitry, each level separated from at least one other level by dielectric material;
- silicon nitride encapsulating the plurality of superimposed levels of integrated circuitry; and
- each level of the plurality of superimposed levels of integrated circuitry residing on a foundation material separated from a donor wafer.
26. A semiconductor die, comprising:
- a plurality of superimposed circuit levels, each being fabricated relative to a segment comprising semiconductive material sheared from a wafer;
- dielectric material located between each circuit level and a semiconductive material-containing segment of a next-higher circuit level;
- dielectric material located below a lowermost circuit level; and
- silicon nitride under the dielectric material located below the lowermost circuit level, silicon nitride over an uppermost circuit level.
27. The semiconductor die of claim 26, wherein sides of the semiconductor die are devoid of silicon nitride.
28. The semiconductor die of claim 27, wherein at least one circuit level of the plurality of circuit levels comprises conductive contacts exposed on at least one side thereof.
29. An integrated circuit structure, comprising:
- a plurality of superimposed levels of integrated circuitry, each level separated from at least one other level by dielectric material, each level comprising multiple un-singulated die sites;
- an acceptor substrate; and
- silicon nitride encapsulating the plurality of superimposed levels of integrated circuitry and between the acceptor substrate and a lowermost circuit level of the superimposed levels.
30. The structure of claim 29, wherein each level of the plurality of superimposed levels of integrated circuitry resides on a foundation material separated from a donor wafer, and a foundation material on which a lowermost level of integrated circuitry resides is bonded to a silicon oxide within the silicon nitride.
31. A semiconductor structure, comprising:
- an acceptor substrate comprising a surface;
- a foundation material bearing circuitry having a dielectric material thereover and positioned on the surface of the acceptor substrate to leave a periphery thereof exposed, the foundation level bearing circuitry comprising multiple un-singulated die sites;
- at least one other foundation material bearing circuitry and positioned on the dielectric material over the foundation material to leave a periphery thereof exposed, the at least one other foundation level bearing circuitry comprising multiple un-singulated die sites; and
- silicon nitride extending over the circuitry borne by the at least one other foundation material and the exposed periphery of the dielectric material covering the circuitry borne by the foundation material to and in contact with silicon nitride that is part of the acceptor substrate.
32. The structure of claim 31, wherein the foundation material and the at least one other foundation material comprise at least three foundation materials, wherein all but a lowermost and an uppermost of the at least three foundation materials resides on a lower foundation material bearing circuitry covered by a dielectric material.
33. A semiconductor structure, comprising:
- an acceptor substrate having a periphery;
- a lowest-most foundation material bearing circuitry and having dielectric material thereover and positioned on the surface of the acceptor substrate to leave a periphery thereof exposed;
- a highest-most foundation material bearing circuitry and having dielectric material thereover and having a periphery thereof exposed;
- at least one intervening level of foundation material bearing circuitry and having dielectric material thereover and having a periphery thereof exposed, the at least one intervening level of foundation material being elevationally between the lowest-most and highest-most foundation materials;
- the periphery of the lowest-most foundation material being set back from the acceptor substrate periphery, the periphery of each intervening level of foundation material being set back from the periphery of the next lower foundation material; and
- silicon nitride extending over the exposed peripheries of the highest-most foundation material and the at least one intervening level of foundation material to and in contact with silicon nitride that is part of the acceptor substrate.
34. The structure of claim 33 wherein the acceptor substrate comprises ceramic material.
35. The structure of claim 33 wherein the acceptor substrate comprises defective semiconductor devices.
36. The structure of claim 33 wherein the acceptor substrate comprises monocrystalline silicon.
37. The structure of claim 20 wherein the lowest-most foundation material, the at least one intervening level of foundation material, and the highest-most foundation material bear circuitry comprising multiple un-singulated die sites.
38. A semiconductor structure, comprising:
- an acceptor substrate having a periphery;
- a lowest-most foundation material bearing circuitry and having dielectric material thereover and positioned on the surface of the acceptor substrate to leave a periphery thereof exposed;
- a highest-most foundation material bearing circuitry and having dielectric material thereover and having a periphery thereof exposed;
- at least one intervening level of foundation material bearing circuitry and having dielectric material thereover and having a periphery thereof exposed, the at least one intervening level of foundation material being elevationally between the lowest-most and highest-most foundation materials;
- the periphery of the lowest-most foundation material being set back from the acceptor substrate periphery, the periphery of each intervening level of foundation material and the highest-most foundation material being peripherally coextensive; and
- silicon nitride extending over the exposed peripheries of the highest-most foundation material and the at least one intervening level of foundation material to and in contact with the silicon nitride on the acceptor substrate surface.
39. The structure of claim 38 wherein the lowest-most foundation material, the at least one intervening level of foundation material, and the highest-most foundation material bear circuitry comprising multiple un-singulated die sites.
Type: Application
Filed: Mar 21, 2014
Publication Date: Jul 24, 2014
Applicant: Micron Technology, Inc. (Boise, ID)
Inventors: Gurtej S. Sandhu (Boise, ID), Kristina K. Parat (Palo Alto, CA)
Application Number: 14/221,655
International Classification: H01L 23/538 (20060101);