CN109935568A - Semiconductor devices and preparation method thereof - Google Patents
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Abstract
本申请公开了半导体器件及其制作方法。该半导体器件的第一结合层和第二结合层彼此接触以提供第一晶片和第二晶片彼此键合,第一结合层和第二结合层的接触面为键合面,第一导电通道和第二导电通道彼此连接以提供第一晶片和第二晶片之间的电连接,第一晶片还包括贯穿第一结合层的第一伪通道,第二晶片还包括贯穿第二结合层的第二伪通道,第一伪通道和第二伪通道彼此接触以提高第一晶片和第二晶片之间的机械连接结合力。该半导体器件在第一晶片和第二晶片的结合层中形成彼此连接的伪通道以改善二者键合面的图案分布,从而提高键合强度和可靠性。
The present application discloses semiconductor devices and fabrication methods thereof. The first bonding layer and the second bonding layer of the semiconductor device are in contact with each other to provide the first wafer and the second wafer are bonded to each other, the contact surface of the first bonding layer and the second bonding layer is a bonding surface, the first conductive channel and The second conductive vias are connected to each other to provide electrical connection between the first wafer and the second wafer, the first wafer further including first dummy vias extending through the first bonding layer, and the second wafer further including second dummy vias extending through the second bonding layer The dummy vias, the first dummy vias and the second dummy vias are in contact with each other to improve the mechanical connection bonding force between the first wafer and the second wafer. In the semiconductor device, dummy vias connected to each other are formed in the bonding layers of the first wafer and the second wafer to improve the pattern distribution of the bonding surfaces of the two, thereby improving the bonding strength and reliability.
Description
技术领域technical field
本发明涉及半导体技术,更具体地,涉及半导体器件及其制作方法。The present invention relates to semiconductor technology, and more particularly, to semiconductor devices and methods of fabricating the same.
背景技术Background technique
半导体技术的发展方向是特征尺寸的减小和集成度的提高。对于存储器件而言,存储器件的存储密度的提高与半导体制造工艺的进步密切相关。随着半导体制造工艺的特征尺寸越来越小,存储器件的存储密度越来越高。The development direction of semiconductor technology is the reduction of feature size and the improvement of integration. For memory devices, the improvement of the storage density of the memory device is closely related to the progress of the semiconductor manufacturing process. As the feature sizes of semiconductor manufacturing processes are getting smaller and smaller, the storage density of memory devices is getting higher and higher.
为了进一步提高存储密度,已经开发出三维结构的存储器件(即,3D存储器件)。该3D存储器件包括沿着垂直方向堆叠的多个存储单元,在单位面积的晶片上可以成倍地提高集成度,并且可以降低成本。进一步地,已经开发出将3D存储器件芯片和驱动电路芯片键合在一起的半导体器件。该半导体器件可以提供存储器件的读写速度,并且提高集成度、降低器件成本和提高可靠性。In order to further increase the storage density, three-dimensionally structured storage devices (ie, 3D storage devices) have been developed. The 3D memory device includes a plurality of memory cells stacked in a vertical direction, and the integration degree can be doubled on a wafer per unit area, and the cost can be reduced. Further, semiconductor devices have been developed in which 3D memory device chips and driving circuit chips are bonded together. The semiconductor device can provide the read and write speed of the memory device, and can improve the integration level, reduce the cost of the device and improve the reliability.
在上述的半导体器件中,晶片之间彼此接触的表面为键合面。晶片的键合面经过清洗和活化处理之后,达到清洁平整的程度。至少两个晶片的键合面彼此接触,在一定的温度和压力条件下,通过范德华力、分子力甚至原子力使晶片键合成为一体。In the above-described semiconductor device, the surfaces of the wafers in contact with each other are bonding surfaces. After the bonding surface of the wafer is cleaned and activated, it is clean and flat. The bonding surfaces of at least two wafers are in contact with each other, and under certain temperature and pressure conditions, the wafers are bonded together by van der Waals force, molecular force or even atomic force.
图1和2示出根据现有技术的半导体器件的截面示意图。半导体器件100包括晶片110和120。晶片110包括半导体衬底111,以及在半导体衬底111上依次堆叠的功能层112和结合层113。晶片120包括半导体衬底121,以及在半导体衬底121上依次堆叠的功能层122和结合层123。其中,半导体衬底和功能层统称为基底。晶片110的结合层113和晶片120的结合层123分别为介质层,例如由二氧化硅组成。图1示出介质层键合工艺,晶片110和120的结合层例如采用热压键合彼此结合形成一体结构。图2示出混合键合工艺,晶片110和120分别包括彼此对准的导电通道114和124,晶片110和120的结合层例如通过热压键合彼此结合形成一体结构,导电通道通过金属键合彼此电连接。1 and 2 show schematic cross-sectional views of a semiconductor device according to the prior art. Semiconductor device 100 includes wafers 110 and 120 . The wafer 110 includes a semiconductor substrate 111 , and a functional layer 112 and a bonding layer 113 sequentially stacked on the semiconductor substrate 111 . The wafer 120 includes a semiconductor substrate 121 , and a functional layer 122 and a bonding layer 123 sequentially stacked on the semiconductor substrate 121 . Among them, the semiconductor substrate and the functional layer are collectively referred to as the substrate. The bonding layer 113 of the wafer 110 and the bonding layer 123 of the wafer 120 are respectively a dielectric layer, for example, composed of silicon dioxide. FIG. 1 shows a dielectric layer bonding process, and the bonding layers of the wafers 110 and 120 are bonded to each other by, for example, thermocompression bonding to form an integrated structure. FIG. 2 shows a hybrid bonding process, the wafers 110 and 120 respectively include conductive channels 114 and 124 aligned with each other, the bonding layers of the wafers 110 and 120 are bonded to each other to form an integral structure, for example, by thermocompression bonding, and the conductive channels are bonded by metal bonding. electrically connected to each other.
然而,在上述的半导体器件中,由于3D存储器件芯片的结构复杂存在着键合强度和可靠性差的问题,期望进一步改进晶片键合工艺以提高键合强度和可靠性。However, in the above-mentioned semiconductor devices, due to the complex structure of the 3D memory device chip, there is a problem of poor bonding strength and reliability, and it is expected to further improve the wafer bonding process to improve the bonding strength and reliability.
发明内容SUMMARY OF THE INVENTION
本发明的目的是提供一种半导体器件及其制作方法,其中,在第一晶片和第二晶片的结合层中形成彼此连接的伪通道以改善二者键合面的图案分布,从而提高键合强度和可靠性。An object of the present invention is to provide a semiconductor device and a manufacturing method thereof, wherein dummy vias connected to each other are formed in the bonding layers of the first wafer and the second wafer to improve the pattern distribution of the bonding surfaces of the two, thereby improving the bonding strength and reliability.
根据本发明的一方面,提供一种半导体器件,包括:According to an aspect of the present invention, a semiconductor device is provided, comprising:
第一晶片,包括第一基底和位于所述第一基底表面的第一结合层、以及贯穿所述第一结合层的第一导电通道和第一伪通道,所述第一导电通道与所述第一基底的互连结构电连接;以及A first wafer includes a first substrate and a first bonding layer on the surface of the first substrate, and a first conductive channel and a first dummy channel penetrating the first bonding layer, the first conductive channel and the the interconnect structure of the first substrate is electrically connected; and
第二晶片,包括第二基底和位于所述第二基底表面的第二结合层、以及贯穿所述第二结合层的第二导电通道和第二伪通道,所述第二导电通道与所述第二基底的互连结构电连接;A second wafer includes a second substrate and a second bonding layer on the surface of the second substrate, and a second conductive via and a second dummy via penetrating the second bonding layer, the second conductive via and the The interconnect structure of the second substrate is electrically connected;
其中,所述第一结合层和所述第二结合层结合,Wherein, the first bonding layer and the second bonding layer are combined,
所述第一导电通道和所述第二导电通道结合以提供所述第一晶片和所述第二晶片之间的电连接和机械连接,所述第一伪通道和所述第二伪通道彼此接触以提高所述第一晶片和所述第二晶片之间的机械连接结合力。The first and second conductive vias combine to provide electrical and mechanical connections between the first and second wafers, the first and second dummy vias to each other contacting to improve the mechanical connection bond between the first wafer and the second wafer.
优选地,所述第一基底包括第一半导体衬底和位于所述第一半导体衬底上的第一功能层,所述第二基底包括第二半导体衬底和位于所述第二半导体衬底上的第二功能层。Preferably, the first substrate includes a first semiconductor substrate and a first functional layer located on the first semiconductor substrate, and the second substrate includes a second semiconductor substrate and a first functional layer located on the second semiconductor substrate on the second functional layer.
优选地,根据所述第一晶片和所述第二晶片的电路互连设置所述第一导电通道和所述第二导电通道的数量和位置,根据所述第一晶片和所述第二晶片之间键合面的金属密度分布设置所述第一伪通道和所述第二伪通道的数量和位置,使得所述键合面的金属密度分布均匀。Preferably, the number and location of the first conductive vias and the second conductive vias are set according to the circuit interconnection of the first wafer and the second wafer, according to the first wafer and the second wafer The number and positions of the first dummy channels and the second dummy channels are set in the metal density distribution of the bonding surfaces between, so that the metal density distribution of the bonding surfaces is uniform.
优选地,所述第一导电通道、所述第二导电通道、所述第一伪通道和所述第二伪通道的横截面形状分别为选自以下形状的任意一种:矩形、方形、三角形、圆形、椭圆形和多边形。Preferably, the cross-sectional shapes of the first conductive channel, the second conductive channel, the first dummy channel and the second dummy channel are respectively any one selected from the following shapes: rectangle, square, triangle , circle, ellipse and polygon.
优选地,所述第一伪通道和所述第二伪通道各自包括第一组伪通道和第二组伪通道,所述第一组伪通道将所述键合面分成面积大致相等的多个区域,所述第二组伪通道分布于多个区域中,使得在所述多个区域的每个区域中,所述第二组伪通道与所述第一导电通道和所述第二导电通道中的相应导电通道共计的金属密度分布均匀。Preferably, the first dummy via and the second dummy via each comprise a first group of dummy vias and a second group of dummy vias, the first group of dummy vias dividing the bonding surface into a plurality of substantially equal areas regions, the second set of dummy vias are distributed in a plurality of regions, such that in each region of the plurality of regions, the second set of dummy vias is associated with the first conductive via and the second conductive via The total metal density distribution of the corresponding conductive channels in the is uniform.
优选地,所述第一导电通道、所述第二导电通道、所述第二组伪通道在所述键合面暴露的截面形状分别为选自以下形状的任意一种:矩形、方形、三角形、圆形、椭圆形和多边形,所述第一组伪通道在所述键合面暴露的截面形状分别为选自以下形状的任意一种:线形和方框形。Preferably, the cross-sectional shapes of the first conductive channel, the second conductive channel, and the second group of dummy channels exposed on the bonding surface are respectively any one selected from the following shapes: rectangle, square, triangle , a circle, an ellipse, and a polygon, and the cross-sectional shape of the first group of dummy channels exposed on the bonding surface is any one selected from the following shapes: a line shape and a box shape.
优选地,所述第一导电通道、所述第二导电通道、所述第一伪通道和所述第二伪通道分别由选自铜、铝、银、铂的金属或合金组成。Preferably, the first conductive channel, the second conductive channel, the first dummy channel and the second dummy channel are respectively composed of metals or alloys selected from copper, aluminum, silver, and platinum.
优选地,所述第一晶片和所述第二晶片包括:3D存储器件芯片和驱动电路芯片。Preferably, the first wafer and the second wafer include: a 3D memory device chip and a driving circuit chip.
优选地,所述第一晶片和所述第二晶片中的至少一个为3D存储器件芯片,所述第一功能层和所述第二功能层中的相应功能层包括:栅叠层结构、沟道柱、层间绝缘层和第一导电通道,所述栅叠层结构包括多个栅极导体层和相邻栅极导体层之间的隔离层,所述沟道柱贯穿所述栅叠层结构。Preferably, at least one of the first wafer and the second wafer is a 3D memory device chip, and the corresponding functional layers in the first functional layer and the second functional layer include: a gate stack structure, a trench a channel pillar, an interlayer insulating layer and a first conductive channel, the gate stack structure includes a plurality of gate conductor layers and an isolation layer between adjacent gate conductor layers, the channel pillar penetrates the gate stack structure.
优选地,所述第一晶片和所述第二晶片中的至少一个为驱动电路芯片,所述第一功能层和所述第二功能层中的相应功能层包括:栅叠层结构、层间绝缘层和第一导电通道,所述栅叠层结构包括栅极导体层。Preferably, at least one of the first wafer and the second wafer is a driving circuit chip, and the corresponding functional layers in the first functional layer and the second functional layer include: a gate stack structure, an interlayer an insulating layer and a first conductive channel, the gate stack structure includes a gate conductor layer.
根据本发明的另一方面,提供一种半导体器件的制作方法,包括:According to another aspect of the present invention, a method for fabricating a semiconductor device is provided, comprising:
形成第一晶片,包括第一基底和位于所述第一基底表面的第一结合层、以及贯穿所述第一结合层的第一导电通道和第一伪通道,所述第一导电通道与所述第一基底的互连结构电连接;A first wafer is formed, including a first substrate and a first bonding layer on the surface of the first substrate, and a first conductive via and a first dummy via penetrating the first bonding layer, the first conductive via and the the interconnection structure of the first substrate is electrically connected;
形成第二晶片,包括第二基底和位于所述第二基底表面的第二结合层、以及贯穿所述第二结合层的第二导电通道和第二伪通道,所述第二导电通道与所述第二基底的互连结构电连接;以及A second wafer is formed, including a second substrate and a second bonding layer on the surface of the second substrate, and a second conductive via and a second dummy via penetrating the second bonding layer, the second conductive via and the the interconnect structure of the second substrate is electrically connected; and
将所述第一晶片和所述第二晶片彼此键合,所述第一结合层和所述第二结合层彼此接触,所述第一结合层和所述第二结合层的接触面为键合面,The first wafer and the second wafer are bonded to each other, the first bonding layer and the second bonding layer are in contact with each other, and the contact surface of the first bonding layer and the second bonding layer is a bond face,
其中,在所述键合步骤中,所述第一导电通道和所述第二导电通道彼此连接以提供所述第一晶片和所述第二晶片之间的电连接和机械连接,所述第一伪通道和所述第二伪通道彼此接触以提高所述第一晶片和所述第二晶片之间的机械连接结合力。wherein, in the bonding step, the first conductive via and the second conductive via are connected to each other to provide electrical and mechanical connections between the first wafer and the second wafer, the first A dummy via and the second dummy via are in contact with each other to improve the mechanical bonding force between the first wafer and the second wafer.
优选地,根据所述第一晶片和所述第二晶片的电路互连设置所述第一导电通道和所述第二导电通道的数量和位置,根据所述第一晶片和所述第二晶片之间键合面的金属密度分布设置所述第一伪通道和所述第二伪通道的数量和位置,使得所述键合面的金属密度分布均匀。Preferably, the number and location of the first conductive vias and the second conductive vias are set according to the circuit interconnection of the first wafer and the second wafer, according to the first wafer and the second wafer The number and positions of the first dummy channels and the second dummy channels are set in the metal density distribution of the bonding surfaces between, so that the metal density distribution of the bonding surfaces is uniform.
优选地,所述第一导电通道、所述第二导电通道、所述第一伪通道和所述第二伪通道在所述键合面暴露的截面形状分别为选自以下形状的任意一种:矩形、方形、三角形、圆形、椭圆形和多边形。Preferably, the cross-sectional shapes of the first conductive via, the second conductive via, the first dummy via and the second dummy via exposed on the bonding surface are any one selected from the following shapes respectively : Rectangle, Square, Triangle, Circle, Ellipse, and Polygon.
优选地,所述第二伪通道的第一组伪通道在所述键合面暴露的截面形状分别为选自以下形状的任意一种:线形和方框形,所述第一导电通道、所述第二导电通道、所述第二伪通道的第二组伪通道在所述键合面暴露的截面形状分别为选自以下形状的任意一种:矩形、方形、三角形、圆形、椭圆形和多边形。Preferably, the cross-sectional shape of the first group of dummy channels exposed on the bonding surface of the second dummy channel is any one selected from the following shapes: a line shape and a square shape, the first conductive channel, the The cross-sectional shape of the second conductive channel and the second group of dummy channels of the second dummy channel exposed on the bonding surface are respectively any one selected from the following shapes: rectangle, square, triangle, circle, ellipse and polygons.
优选地,所述第一导电通道和所述第一伪通道采用共同的金属填充工艺形成,所述第二导电通道和所述第二伪通道采用共同的金属填充工艺形成,所述金属填充工艺包括:Preferably, the first conductive via and the first dummy via are formed by a common metal filling process, the second conductive via and the second dummy via are formed by a common metal filling process, and the metal filling process include:
在所述第一结合层和所述第二结合层中的相应结合层中形成贯穿的开口;forming through openings in respective ones of the first bonding layer and the second bonding layer;
采用金属层填充所述开口;以及filling the opening with a metal layer; and
采用化学机械平面化去除所述金属层位于所述相应结合层表面的部分。Chemical mechanical planarization is used to remove the portion of the metal layer on the surface of the corresponding bonding layer.
根据本发明实施例的半导体器件,不仅在第一晶片和第二晶片的结合层中形成用于彼此电连接的导电通道,而且形成用于彼此机械连接的伪通道。该半导体器件中的导电通道提供第一晶片和第二晶片之间的电连接,伪通道提供第一晶片和第二晶片之间的机械连接。According to the semiconductor device of the embodiment of the present invention, not only conductive vias for electrical connection to each other but also dummy vias for mechanical connection to each other are formed in the bonding layers of the first wafer and the second wafer. Conductive vias in the semiconductor device provide electrical connections between the first and second wafers, and dummy vias provide mechanical connections between the first and second wafers.
该半导体器件中的伪通道提高了键合面的金属密度,使得金属键相对于分子键的比例也提高。采用金属材料形成的伪通道具有良好的延展性,即使伪通道的连接端部凸凹不平,或者存在着晶片翘曲,也能实现良好的机械连接,从而可以提高混合键合的键合强度。此外,随着键合面的金属密度的提高,可以改善半导体器件的散热特性。The dummy channel in the semiconductor device increases the metal density of the bonding surface, so that the ratio of metal bonds to molecular bonds is also increased. The dummy channel formed of metal material has good ductility, and even if the connection end of the dummy channel is uneven, or there is wafer warpage, a good mechanical connection can be achieved, so that the bonding strength of the hybrid bonding can be improved. In addition, as the metal density of the bonding surface increases, the heat dissipation characteristics of the semiconductor device can be improved.
进一步地,该半导体器件的伪通道使得金属密度分布均匀,从而在化学机械平面化步骤中可以获得光滑平整的键合面,从而在随后的键合步骤中增加接触面积,从而以提高键合强度和可靠性。Further, the dummy channel of the semiconductor device makes the metal density distribution uniform, so that a smooth and flat bonding surface can be obtained in the chemical mechanical planarization step, thereby increasing the contact area in the subsequent bonding step, thereby improving the bonding strength. and reliability.
因此,根据本发明实施例的半导体器件提高产品良率和可靠性。Therefore, the semiconductor device according to the embodiment of the present invention improves product yield and reliability.
附图说明Description of drawings
通过以下参照附图对本发明实施例的描述,本发明的上述以及其他目的、特征和优点将更为清楚。The above and other objects, features and advantages of the present invention will become more apparent from the following description of embodiments of the present invention with reference to the accompanying drawings.
图1和2示出根据现有技术的半导体器件的截面示意图。1 and 2 show schematic cross-sectional views of a semiconductor device according to the prior art.
图3至7分别示出根据本发明实施例的半导体器件制作方法的不同步骤的截面示意图。3 to 7 respectively illustrate schematic cross-sectional views of different steps of a method for fabricating a semiconductor device according to an embodiment of the present invention.
图8a和8b分别示出根据本发明实施例的半导体器件的键合面的平面示意图。8a and 8b respectively illustrate schematic plan views of bonding surfaces of a semiconductor device according to an embodiment of the present invention.
具体实施方式Detailed ways
以下将参照附图更详细地描述本发明。在各个附图中,相同的元件采用类似的附图标记来表示。为了清楚起见,附图中的各个部分没有按比例绘制。此外,可能未示出某些公知的部分。为了简明起见,可以在一幅图中描述经过数个步骤后获得的半导体结构。The present invention will be described in more detail below with reference to the accompanying drawings. In the various figures, like elements are designated by like reference numerals. For the sake of clarity, various parts in the figures have not been drawn to scale. Additionally, some well-known parts may not be shown. For the sake of simplicity, the semiconductor structure obtained after several steps can be depicted in one figure.
应当理解,在描述器件的结构时,当将一层、一个区域称为位于另一层、另一个区域“上面”或“上方”时,可以指直接位于另一层、另一个区域上面,或者在其与另一层、另一个区域之间还包含其它的层或区域。并且,如果将器件翻转,该一层、一个区域将位于另一层、另一个区域“下面”或“下方”。It will be understood that, in describing the structure of a device, when a layer or region is referred to as being "on" or "over" another layer or region, it can be directly on the other layer or region, or Other layers or regions are also included between it and another layer, another region. And, if the device is turned over, the layer, one region, will be "under" or "under" another layer, another region.
如果为了描述直接位于另一层、另一个区域上面的情形,本文将采用“直接在……上面”或“在……上面并与之邻接”的表述方式。In order to describe the situation directly above another layer, another area, the expression "directly on" or "on and adjacent to" will be used herein.
在下文中描述了本发明的许多特定的细节,例如器件的结构、材料、尺寸、处理工艺和技术,以便更清楚地理解本发明。但正如本领域的技术人员能够理解的那样,可以不按照这些特定的细节来实现本发明。Numerous specific details of the present invention are described below, such as device structures, materials, dimensions, processing techniques and techniques, in order to provide a clearer understanding of the present invention. However, as can be understood by one skilled in the art, the present invention may be practiced without these specific details.
在本申请中,术语“半导体结构”指在制造存储器件的各个步骤中形成的整个半导体结构的统称,包括已经形成的所有层或区域。在下文中,除非特别指出,“半导体结构”指的是包括晶片及其上形成的栅叠层结构的中间结构。In this application, the term "semiconductor structure" refers collectively to the entire semiconductor structure formed during the various steps of fabricating a memory device, including all layers or regions that have already been formed. Hereinafter, unless otherwise specified, "semiconductor structure" refers to an intermediate structure including a wafer and a gate stack structure formed thereon.
本申请的发明人发现,现有的半导体器件应用于3D存储器件芯片存在着以下问题。介质层键合工艺要求键合面的平整度高,例如小于0.3至0.5纳米。然而,3D存储器件芯片的面积较大,晶片翘曲的存在严重影响键合质量。混合键合工艺在形成晶片互连结构的同时还实现晶片之间的电连接,因此,在3D存储器件芯片中的应用更有吸引力。然而,在混合键合工艺中,键合面存在着导电通道图案,导电通道在键合面上形成凸部或凹部,使得介质层或导电通道的匹配难度大,导致键合强度降低。半导体器件中彼此键合的晶片键合强度差,甚至容易脱落,使得产品良率受到极大的影响。The inventors of the present application found that the application of the existing semiconductor device to a 3D memory device chip has the following problems. The dielectric layer bonding process requires that the flatness of the bonding surface is high, for example, less than 0.3 to 0.5 nanometers. However, the area of 3D memory device chips is large, and the existence of wafer warpage seriously affects the bonding quality. The hybrid bonding process also realizes the electrical connection between the wafers while forming the wafer interconnect structure, so the application in 3D memory device chips is more attractive. However, in the hybrid bonding process, a conductive channel pattern exists on the bonding surface, and the conductive channel forms a convex portion or a concave portion on the bonding surface, which makes it difficult to match the dielectric layer or the conductive channel, resulting in a decrease in the bonding strength. The wafers bonded to each other in the semiconductor device have poor bonding strength and even fall off easily, which greatly affects the product yield.
本申请的发明人注意上述现有技术仅仅根据晶片的电路结构设计导电通道图案,而没有根据至少两个晶片的键合特性设计导电通道图案,因此提出进一步改进的键合工艺,其中,在第一晶片和第二晶片的结合层中形成彼此连接的伪通道以改善二者键合面的图案分布,从而提高键合强度和可靠性。The inventors of the present application have noticed that the above-mentioned prior art only designs the conductive channel pattern according to the circuit structure of the wafer, but does not design the conductive channel pattern according to the bonding characteristics of at least two wafers, and therefore proposes a further improved bonding process, wherein, in the No. Dummy channels connected to each other are formed in the bonding layers of the first wafer and the second wafer to improve the pattern distribution of the bonding surfaces of the two wafers, thereby improving the bonding strength and reliability.
本发明可以各种形式呈现,以下将描述其中一些示例。The invention may be embodied in various forms, some examples of which will be described below.
图3至7分别示出根据本发明实施例的半导体器件制作方法的不同步骤的截面示意图。3 to 7 respectively illustrate schematic cross-sectional views of different steps of a method for fabricating a semiconductor device according to an embodiment of the present invention.
如图3所示,该方法开始于已经形成主要器件结构的晶片210。As shown in FIG. 3, the method begins with a wafer 210 on which primary device structures have been formed.
晶片210包括半导体衬底211,以及在半导体衬底211依次堆叠的功能层212和结合层213。半导体衬底211例如为硅衬底。功能层212例如是包括栅叠层结构、层间绝缘层和导电通道的多层结构。结合层213为介质层,例如由氧化硅组成。在图3所示的实施例中,功能层212包括贯穿其中的导电通道216。其中,半导体衬底211和在半导体衬底211上堆叠的功能层212统称为基底。The wafer 210 includes a semiconductor substrate 211 , and a functional layer 212 and a bonding layer 213 sequentially stacked on the semiconductor substrate 211 . The semiconductor substrate 211 is, for example, a silicon substrate. The functional layer 212 is, for example, a multi-layer structure including a gate stack structure, an interlayer insulating layer, and a conductive channel. The bonding layer 213 is a dielectric layer, for example, composed of silicon oxide. In the embodiment shown in FIG. 3, functional layer 212 includes conductive vias 216 therethrough. The semiconductor substrate 211 and the functional layer 212 stacked on the semiconductor substrate 211 are collectively referred to as a base.
晶片210的功能层的内部结构与芯片类型有关。该功能层提供了晶体管的至少一部分结构。例如,晶片210的半导体衬底211中形成晶体管的源区和漏区,功能层212中形成晶体管的栅叠层结构。在晶片210为3D存储器件芯片的情形下,功能层212中的栅叠层结构包括多个层面的栅极导体层和用于隔开相邻栅极导体层的多个层间绝缘层,以及贯穿栅叠层结构的沟道柱。在晶片210为驱动电路芯片的情形下,功能层212中的栅叠层结构例如包括单个层面的栅极导体层。The internal structure of the functional layers of the wafer 210 is related to the chip type. The functional layer provides at least part of the structure of the transistor. For example, the source region and the drain region of the transistor are formed in the semiconductor substrate 211 of the wafer 210 , and the gate stack structure of the transistor is formed in the functional layer 212 . In the case where the wafer 210 is a 3D memory device chip, the gate stack structure in the functional layer 212 includes a plurality of levels of gate conductor layers and a plurality of interlayer insulating layers for separating adjacent gate conductor layers, and through the channel pillars of the gate stack structure. In the case where the wafer 210 is a driving circuit chip, the gate stack structure in the functional layer 212 includes, for example, a single-level gate conductor layer.
在结合层213的表面形成抗蚀剂层201。采用光刻工艺在抗蚀剂层201中形成多个开口202,从而形成掩膜。抗蚀剂层201中的多个开口202不仅包括与导电通道216对齐的第一开口,而且包括与导电通道216未对齐的第二开口。如下文所述,第一开口将用于形成提供电连接的导电通道,第二开口将用于形成改善图案分布的伪通道。The resist layer 201 is formed on the surface of the bonding layer 213 . A plurality of openings 202 are formed in the resist layer 201 using a photolithography process, thereby forming a mask. The plurality of openings 202 in the resist layer 201 include not only first openings that are aligned with the conductive vias 216 , but also second openings that are not aligned with the conductive vias 216 . As described below, the first openings will be used to form conductive vias that provide electrical connections, and the second openings will be used to form dummy vias that improve pattern distribution.
然后,采用抗蚀剂层201作为掩膜进行蚀刻,在结合层213中形成多个开口203,从而将抗蚀剂层201的图案转移至结合层213中,如图4所示。Then, etching is performed using the resist layer 201 as a mask to form a plurality of openings 203 in the bonding layer 213, so that the pattern of the resist layer 201 is transferred into the bonding layer 213, as shown in FIG. 4 .
该步骤例如采用干法蚀刻(例如反应离子蚀刻)或湿法蚀刻工艺。在干法蚀刻中使用的蚀刻剂例如是蚀刻气体,在湿法蚀刻中使用的蚀刻剂例如是蚀刻溶液。在蚀刻期间,蚀刻剂经由抗蚀剂层201中的开口202到达结合层213的表面,从而逐渐去除结合层213的暴露部分。由于蚀刻剂选择性,或者通过控制蚀刻时间,蚀刻可以停止于导电通道216的顶端表面。然后,采用灰化或溶剂溶解去除抗蚀剂层201。This step, for example, employs a dry etching (eg reactive ion etching) or wet etching process. The etchant used in dry etching is, for example, an etching gas, and the etchant used in wet etching is, for example, an etching solution. During etching, the etchant reaches the surface of the bonding layer 213 via the openings 202 in the resist layer 201 , gradually removing the exposed portions of the bonding layer 213 . Etching can be stopped at the top surface of the conductive channel 216 due to etchant selectivity, or by controlling the etch time. Then, the resist layer 201 is removed by ashing or solvent dissolution.
然后,在结合层213上沉积金属层204,如图5所示。Then, a metal layer 204 is deposited on the bonding layer 213 as shown in FIG. 5 .
该步骤例如采用磁控溅射形成金属层204。该金属层例如由选自铂、银、铜、铝的金属或合金组成,优选地,由铜组成。该金属层204填充结合层213中的多个开口203,并且在结合层213的表面横向延伸。In this step, the metal layer 204 is formed by, for example, magnetron sputtering. The metal layer consists, for example, of a metal or alloy selected from platinum, silver, copper, aluminum, preferably copper. The metal layer 204 fills the plurality of openings 203 in the bonding layer 213 and extends laterally across the surface of the bonding layer 213 .
然后,采用化学机械平面化工艺去除金属层204位于结合层213表面上的部分,形成导电通道214和伪通道215,如图6所示。Then, a chemical mechanical planarization process is used to remove the portion of the metal layer 204 located on the surface of the bonding layer 213 to form a conductive channel 214 and a dummy channel 215, as shown in FIG. 6 .
该步骤采用的化学机械平面化工艺,以结合层213作为停止层,从而可以完全去除金属层204位于结合层213表面上的部分。金属层204位于所述多个开口203的第一开口中的部分形成导电通道214,位于所述多个开口203的第二开口中的部分形成伪通道215。The chemical mechanical planarization process used in this step uses the bonding layer 213 as a stop layer, so that the part of the metal layer 204 located on the surface of the bonding layer 213 can be completely removed. Portions of the metal layer 204 located in the first openings of the plurality of openings 203 form conductive vias 214 , and portions of the metal layer 204 located in the second openings of the plurality of openings 203 form dummy vias 215 .
结合层213中的导电通道214与功能层212中的导电通道216形成连续的导电路径,结合层213中的伪通道215用于改善图案分布,而未形成导电路径。The conductive channels 214 in the bonding layer 213 and the conductive channels 216 in the functional layer 212 form continuous conductive paths, and the dummy channels 215 in the bonding layer 213 are used to improve pattern distribution without forming conductive paths.
然后,在晶片220中形成与晶片210彼此对准和相同的导电通道224和伪通道225,将晶片210和220的结合层彼此接触以形成半导体器件200,如图7所示。Then, conductive vias 224 and dummy vias 225 are formed in wafer 220 in alignment with and identical to each other with wafer 210 , and the bonding layers of wafers 210 and 220 are contacted to each other to form semiconductor device 200 , as shown in FIG. 7 .
晶片220包括半导体衬底221,以及在半导体衬底221依次堆叠的功能层222和结合层223。半导体衬底221例如为硅衬底。功能层222例如是包括栅叠层结构、层间绝缘层和导电通道的多层结构。结合层223为介质层,例如由氧化硅组成。在图7所示的实施例中,功能层222包括贯穿其中的导电通道226。The wafer 220 includes a semiconductor substrate 221 , and a functional layer 222 and a bonding layer 223 sequentially stacked on the semiconductor substrate 221 . The semiconductor substrate 221 is, for example, a silicon substrate. The functional layer 222 is, for example, a multi-layer structure including a gate stack structure, an interlayer insulating layer, and a conductive channel. The bonding layer 223 is a dielectric layer, for example, composed of silicon oxide. In the embodiment shown in FIG. 7, functional layer 222 includes conductive vias 226 therethrough.
结合层223中的导电通道与功能层222中的导电通道226形成连续的导电路径,结合层223中的伪通道225用于改善图案分布,而未形成导电路径。因此,在键合过程中,晶片210的导电通道214与晶片220的导电通道224彼此接触且金属键合,从而提供晶片210和220之间的电连接,晶片210的伪通道215与晶片220的伪通道225彼此接触且金属键合,从而提供晶片210和220之间的机械连接。The conductive channels in the bonding layer 223 and the conductive channels 226 in the functional layer 222 form continuous conductive paths, and the dummy channels 225 in the bonding layer 223 are used to improve pattern distribution without forming conductive paths. Thus, during the bonding process, the conductive vias 214 of the wafer 210 and the conductive vias 224 of the wafer 220 are in contact with each other and metal-bonded, thereby providing electrical connections between the wafers 210 and 220 , the dummy vias 215 of the wafer 210 and the wafer 220 Dummy vias 225 are in contact with each other and are metal-bonded to provide a mechanical connection between wafers 210 and 220 .
图8a和8b分别示出根据本发明实施例的半导体器件的键合面的平面示意图。在本发明的实施例中,半导体器件的的键合面为结合层的自由表面。半导体器件200中的晶片210和220的键合面图案分布大致相同。在图中示出沿着图7中的线AA观察晶片210的平面示意图。8a and 8b respectively illustrate schematic plan views of bonding surfaces of a semiconductor device according to an embodiment of the present invention. In the embodiment of the present invention, the bonding surface of the semiconductor device is the free surface of the bonding layer. The bonding surface pattern distributions of the wafers 210 and 220 in the semiconductor device 200 are approximately the same. A schematic plan view of wafer 210 viewed along line AA in FIG. 7 is shown in the figure.
如图8a和8b所示,晶片210的结合层213的表面为键合面。在键合面上分布多个导电通道214和多个伪通道215。根据晶片210和220的电路互连设计导电通道214的数量和位置,以提供内部电路经由键合面的电连接。根据晶片210的金属密度分布设计伪通道215的数量和位置。在该实施例中,由于伪通道215的引入,可以改善键合面上的金属密度的分布,即,导电通道和伪通道共计的金属图案面积与键合面的表面积比例,在键合面的不同区域中大致相等。As shown in FIGS. 8 a and 8 b , the surface of the bonding layer 213 of the wafer 210 is a bonding surface. A plurality of conductive vias 214 and a plurality of dummy vias 215 are distributed on the bonding surface. The number and location of conductive vias 214 are designed in accordance with the circuit interconnections of wafers 210 and 220 to provide electrical connection of internal circuits via bond surfaces. The number and location of the dummy vias 215 are designed according to the metal density distribution of the wafer 210 . In this embodiment, due to the introduction of the dummy channel 215, the distribution of metal density on the bonding surface can be improved, that is, the ratio of the total metal pattern area of the conductive channel and the dummy channel to the surface area of the bonding surface, on the bonding surface roughly equal in different regions.
在图8a所示的实施例中,伪通道215的截面形状与多个导电通道214的截面形状通道大致相同,均为矩形。在替代的实施例中,该截面形状可以是矩形、方形、三角形、圆形、椭圆形和多边形中的任意一种。多个伪通道215填充多个导电通道214周围的空白区域,以改善金属密度的分布。In the embodiment shown in FIG. 8 a , the cross-sectional shape of the dummy via 215 is substantially the same as the cross-sectional shape of the plurality of conductive vias 214 , and both are rectangular. In alternative embodiments, the cross-sectional shape may be any of a rectangle, a square, a triangle, a circle, an ellipse, and a polygon. The plurality of dummy vias 215 fill empty areas around the plurality of conductive vias 214 to improve the distribution of metal density.
在图8b所示的实施例中,伪通道215包括第一组伪通道215a和第二组伪通道215b。第一组伪通道215a的截面形状为线形或方框形,用于将晶片210的键合面分成多个面积大致相等的区域。在每个区域中,伪通道215b的截面形状与多个导电通道214的截面形状通道大致相同,均为矩形。在替代的实施例中,该截面形状可以是矩形、方形、三角形、圆形、椭圆形和多边形中的任意一种。多个伪通道215b填充多个导电通道214周围的空白区域。In the embodiment shown in Figure 8b, the dummy channel 215 includes a first set of dummy channels 215a and a second set of dummy channels 215b. The cross-sectional shape of the first group of dummy vias 215a is linear or square, and is used to divide the bonding surface of the wafer 210 into a plurality of regions with substantially equal areas. In each area, the cross-sectional shape of the dummy via 215b is substantially the same as the cross-sectional shape of the plurality of conductive vias 214, and both are rectangular. In alternative embodiments, the cross-sectional shape may be any of a rectangle, a square, a triangle, a circle, an ellipse, and a polygon. The plurality of dummy vias 215b fill empty areas around the plurality of conductive vias 214 .
根据本发明实施例的半导体器件,不仅在结合层中形成用于电连接的导电通道,而且形成用于改善金属分布的伪通道。第一晶片和第二晶片的导电通道和伪通道分别对准,其中仅导电通道与内部电路电连接,伪通道未形成导电路径。该半导体器件可以提高键合强度和可靠性,从而提高产品良率。According to the semiconductor device of the embodiment of the present invention, not only conductive vias for electrical connection but also dummy vias for improving metal distribution are formed in the bonding layer. The conductive vias and the dummy vias of the first wafer and the second wafer are aligned, respectively, wherein only the conductive vias are electrically connected to the internal circuit, and the dummy vias do not form conductive paths. The semiconductor device can improve bonding strength and reliability, thereby improving product yield.
在以上的描述中,对于各层的构图、蚀刻等技术细节并没有做出详细的说明。但是本领域技术人员应当理解,可以通过各种技术手段,来形成所需形状的层、区域等。另外,为了形成同一结构,本领域技术人员还可以设计出与以上描述的方法并不完全相同的方法。另外,尽管在以上分别描述了各实施例,但是这并不意味着各个实施例中的措施不能有利地结合使用。In the above description, technical details such as patterning and etching of each layer are not described in detail. However, those skilled in the art should understand that various technical means can be used to form layers, regions, etc. of desired shapes. In addition, in order to form the same structure, those skilled in the art can also design methods that are not exactly the same as those described above. Additionally, although the various embodiments have been described above separately, this does not mean that the measures in the various embodiments cannot be used in combination to advantage.
以上对本发明的实施例进行了描述。但是,这些实施例仅仅是为了说明的目的,而并非为了限制本发明的范围。本发明的范围由所附权利要求及其等价物限定。不脱离本发明的范围,本领域技术人员可以做出多种替代和修改,这些替代和修改都应落在本发明的范围之内。Embodiments of the present invention have been described above. However, these examples are for illustrative purposes only, and are not intended to limit the scope of the present invention. The scope of the invention is defined by the appended claims and their equivalents. Without departing from the scope of the present invention, those skilled in the art can make various substitutions and modifications, and these substitutions and modifications should all fall within the scope of the present invention.
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