US20150206842A1 - Semiconductor device and method of manufacturing the same - Google Patents
Semiconductor device and method of manufacturing the same Download PDFInfo
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- US20150206842A1 US20150206842A1 US14/478,996 US201414478996A US2015206842A1 US 20150206842 A1 US20150206842 A1 US 20150206842A1 US 201414478996 A US201414478996 A US 201414478996A US 2015206842 A1 US2015206842 A1 US 2015206842A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/52—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames
- H01L23/522—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body
- H01L23/532—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body characterised by the materials
- H01L23/53204—Conductive materials
- H01L23/53276—Conductive materials containing carbon, e.g. fullerenes
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- H10W20/4462—
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/70—Manufacture or treatment of devices consisting of a plurality of solid state components formed in or on a common substrate or of parts thereof; Manufacture of integrated circuit devices or of parts thereof
- H01L21/71—Manufacture of specific parts of devices defined in group H01L21/70
- H01L21/768—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics
- H01L21/76838—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics characterised by the formation and the after-treatment of the conductors
- H01L21/76841—Barrier, adhesion or liner layers
- H01L21/76871—Layers specifically deposited to enhance or enable the nucleation of further layers, i.e. seed layers
- H01L21/76876—Layers specifically deposited to enhance or enable the nucleation of further layers, i.e. seed layers for deposition from the gas phase, e.g. CVD
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/52—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames
- H01L23/522—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body
- H01L23/5226—Via connections in a multilevel interconnection structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/52—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames
- H01L23/522—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body
- H01L23/528—Layout of the interconnection structure
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- H10W20/037—
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- H10W20/039—
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- H10W20/045—
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- H10W20/0633—
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- H10W20/42—
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- H10W20/43—
Definitions
- Embodiments described herein relate generally to a semiconductor device using graphene for interconnecting an LSI and a method of manufacturing the same.
- FIG. 1 is a cross-sectional view illustrating the schematic structure of a semiconductor device according to a first embodiment
- FIGS. 2A to 2E are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a second embodiment
- FIGS. 3A and 3B are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a third embodiment
- FIGS. 4A to 4F are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a fourth embodiment
- FIG. 5 is a cross-sectional view illustrating the schematic structure of a semiconductor device according to a fifth embodiment
- FIG. 6 is a graph illustrating the relationship between interconnect width and resistance of graphene.
- FIGS. 7A and 7B are plan and a sectional view to explain the example of the modification.
- a semiconductor device using graphene comprising a catalyst layer formed on or in a substrate along with an interconnect pattern and a graphene layer formed on the catalyst layer.
- the graphene layer is arranged parallel to a narrower linewidth than the width of the interconnect pattern.
- graphene Since graphene exhibits quantized conduction properties as mentioned above, it can be used as an interconnect having ultimately low resistance instead of a metallic interconnect and is advantageous with respect to electrical conduction in a long-distance interconnect. Also, graphene has excellent consistency for a process of forming a device interconnect, since the structure of graphene itself is an extremely thin film and graphene can be formed by a CVD method.
- SW-GNR refers to a single-layer graphene and “SW-CNT” a single-layer carbon nanotube.
- the resistance remains almost constant in a fine interconnect width as a result of the quantum effect, regardless of linewidth.
- the resistance of graphene is by far lower than that of Cu in a region having a width of approximately 10 nm or less because of quantized conduction properties. This reveals that the graphene is effective in a narrow-linewidth interconnect and not effective in a wide-linewidth interconnect.
- the purpose of the present embodiment is to reduce interconnect resistance by separating graphene into a plurality of pieces having a narrow linewidth. That is, although by separating graphene into a plurality of pieces having a width of tens of nm, the resistance of each piece of graphene gets slightly higher than that of graphene having the original width, the total resistance of the plurality of pieces gets substantially lower than that of graphene having the original width by connecting a plurality of pieces in parallel.
- the purpose of the present embodiment is to thereby reduce the resistance of a graphene interconnect.
- FIG. 1 is a cross-sectional view illustrating the schematic structure of a semiconductor device according to a first embodiment.
- a plurality of interconnect layers 20 are formed on a substrate. A part of the interconnect layers 20 are connected to a lower semiconductor element and an upper interconnect layer through a contact via.
- the first embodiment has a novel LSI interconnect structure using graphene to the material of the interconnect layers 20 and is characterized in that graphene is separated particularly in a wide-width interconnect. In the following, a detailed description will be given.
- a first contact layer insulating film 11 is formed on a Si substrate 10 , on which semiconductor elements such as transistor and capacitor are formed.
- a lower contact via 12 which is configured to connect a lower-layer semiconductor element and an upper-layer interconnect layer, is embedded and formed in the insulating film 11 .
- An interconnect layer insulating film 13 is formed on the insulating film 11 , on which the contact via 12 is formed.
- a plurality of interconnect grooves 14 are formed in the insulating film 13 .
- the structure of forming the contact layer insulating film 11 and the contact via 12 on the Si substrate 10 is defined as a substrate. Also, it is possible to define a substrate including the interconnect layer insulating film 13 on the contact layer insulating film 11 .
- a catalyst underlayer 21 which is configured to promote uniform growth of a graphene layer, is formed on the bottom face and the side face of the interconnect grooves 14 . Further, a metallic catalyst layer 22 , which is configured to grow a graphene layer, is formed on the catalyst layer 21 so as to embed the interconnect grooves 14 . A graphene layer 23 , which functions as an electrically conductive layer, is formed on the metallic catalyst layer 22 .
- the interconnect layers 20 consist of the catalyst underlayer 21 , the metallic catalyst layer 22 and the graphene layer 23 .
- the graphene layer 23 is formed on the whole surface of the catalyst layer 22 in an interconnect layer 20 a , which has a narrow linewidth (for example, 10 nm or less).
- the graphene layer 23 is separated into a plurality of layers in an interconnect layer 20 b , which has a wide linewidth. That is, a graphene separation layer 24 is formed on the catalyst layer 22 to separate the graphene layer 23 to a width of, for example, 10 nm or less.
- the interconnect layer 20 b is connected to the contact via 12 in FIG. 1 , it may also be possible that the interconnect layer 20 a is connected to the contact via 12 .
- a graphene layer is a layer where a plurality of graphene sheets are laminated in a direction non-parallel to the surface of a substrate.
- a plurality of graphene sheets are laminated in a vertical direction to the surface of the metallic catalyst layer 22 .
- Such graphene layers are arranged side by side in a parallel direction to the surface of the metallic catalyst layer 22 .
- a second contact layer insulating film 25 is formed on the interconnect layer insulating film 13 , on which the interconnect layers 20 are formed.
- a contact via 26 is embedded and formed in the insulating film 25 .
- the contact via 26 is configured to contact the graphene layer 23 of the interconnect layer 20 a . Note that the contact via 26 may be formed so as to contact the interconnect layer 20 b.
- the catalyst underlayer 21 is an auxiliary film for promoting uniform growth of the graphene layer 23 . Also, the catalyst underlayer 21 plays a role in preventing diffusion into the insulating film and the underlayer contact from the metallic catalyst layer 22 .
- the typical materials of the catalyst underlayer 21 include Ta, Ti, Ru, W and Al. Also, it is possible to use the nitride and oxide of these films and a laminating material containing these films.
- the metallic catalyst layer 22 is a layer necessary for growing graphene. It is preferable that any of single metals, Co, Ni, Fe, Ru and Cu is used for the material of the metallic catalyst layer 22 . It is also preferable that alloy containing at least any of them or carbide of them is used for the material of the metallic catalyst layer 22 . It is desirable that the catalyst layer 22 of graphene be a continuous film. It is therefore necessary that the catalyst layer 22 be formed to have a thickness of at least 0.5 nm to be a continuous film. Graphene itself cannot grow well in a state where the catalyst layer 22 is diffused and microparticulated. Further graphene layer might be formed in discontinuity. Accordingly, it is necessary that the catalyst 22 be formed to have a thickness enough to be a continuous film, in order to form uniform continuous graphene layers.
- the graphene layer 23 is a layer on which novel carbon materials having extremely thin graphite are laminated. Also, the graphene layer 23 can be used instead of a metallic interconnect to realize an interconnect having ultimately low resistance as a result of quantized conduction. In the structure of the first embodiment, graphene functioning as an electrically conductive layer is formed as a laminated layer.
- the graphene separation layer 24 is formed so as to form a plural pieces of graphene narrower than an interconnect width in a longitudinal direction of the interconnect.
- the materials of the graphene separation layer 24 include a hardmask material and inhibit graphene growth on the surface of the separation layer 24 .
- a hardmask material for example, it is possible to use Ta, Ti, Ru, W, Al, Si and the like, and nitride or oxide of material thereof.
- a low-resistance material can be used for the separation layer 24 to use it as a part of the electrically conductive layer.
- a material that functions as dopant can be used to dope other elements into graphene.
- a diffusion barrier layer such as SiN is formed so as to cover the above-mentioned interconnect structure.
- the structure in the first embodiment is the same as a conventional graphene interconnect structure when the linewidth is narrow, and narrow-width graphene is formed in parallel when the linewidth is wide.
- This realizes a graphene interconnect structure suitable for doping while exploiting the quantized conduction of graphene. Therefore, it is possible to reduce interconnect resistance and contribute to improving the performance of a semiconductor device.
- With a wide-width interconnect it is also possible to increase the ratio of sidewalls by forming a narrow-width graphene in parallel as an electrically conductive layer. It is thereby possible to easily dope other elements into the graphene.
- FIGS. 2A to 2E are cross-sectional views illustrating the process of manufacturing the semiconductor device according to the second embodiment. Note that while the position of the contact via is different from that of FIG. 1 , it is possible that the position is the same as in FIG. 1 .
- the first contact layer insulating film 11 such as TEOS is formed on the Si substrate 10 , on which semiconductor elements such as transistor and capacitor are formed.
- the lower contact via 12 which is configured to connect the semiconductor element of a lower layer and the interconnect layer of an upper layer, is embedded and formed in the insulating film 11 .
- a single metal such as W, Cu and Al is used for conductive material as the contact via 12 .
- the interconnect layer insulating film 13 such as SiO 2 film and SIOC film is formed on the insulating film 11 . If a sufficient selection ratio between the contact layer insulating film 11 and the interconnect layer insulating layer 13 cannot be obtained, a stopper layer such as SiCN can be formed on the upper face of the contact layer insulating film 11 .
- the plurality of interconnect grooves 14 which are configured to form an interconnect layer, are formed in the interconnect layer insulating layer 13 by RIE or the like.
- the catalyst underlayer 21 which functions as an auxiliary film for facilitating preparation of a graphene layer, is formed on the bottom face and the side face of each of the plurality of interconnect grooves 14 .
- the metallic catalyst layer 22 for growing a graphene layer is formed on the catalyst underlayer 21 .
- the left side corresponds to the interconnect layer 20 a having a narrow linewidth and the right side corresponds to the interconnect layer 20 b having a wide linewidth.
- An underlayer material and a catalyst material are as mentioned above. The surface is then flattened after a CMP process.
- a fine line that functions as the graphene separation layer 24 is formed on a portion that functions as a wide-linewidth interconnect portion.
- a separation layer material film is formed on the whole surface, and a resist is formed thereon.
- the plurality of graphene separation layers 24 are formed by photolithography and RIE so that the width of the exposed portion of the metallic catalyst layer 22 is narrower than a predetermined interconnect width.
- the materials of the separation layer 24 are as described above.
- a predetermined interconnect width is defined as follows. When a linewidth is made less than that of a narrow interconnect by dividing a wide-linewidth interconnect, processing is not possible. Therefore, it is necessary to make the width of a divided graphene wider than a processable narrow interconnect width.
- the width of a wide interconnect is three times wider than that of a narrow interconnect, since at least two pieces of graphene having a width wider than the width of the narrow interconnect need to be arranged. Therefore, a dividable interconnect is an interconnect three times wider than the narrowest interconnect in the same layer. That is, when the smallest width that can be formed by fine processing is 10 nm, a predetermined interconnect width is 30 nm. Note that a predetermined interconnect width can be further reduced when the smallest width decreases.
- the graphene layer 23 which functions as an electrical conductive layer, is formed.
- the graphene layer 23 is formed by a CVD method. Hydrocarbon series gas such as methane and acetylene or mixed gas thereof is used for the carbon source of a CVD method, and hydrogen and rare gas are used for carrier gas.
- the graphene layer 23 has a feature of being formed only on the catalyst layer 22 , which is a continuous layer, not on the surface of the graphene separation layer 24 .
- gas containing a doping element into material gas for purpose of doping into graphene. It is also possible to perform processing such as anneal under a doping material atmosphere for the same purpose.
- the elements of groups 14 to 17 are used for doping material; N, Cl, Br and a reactant containing them are used. There is also a case where a metal such as Fe is included.
- the structure substantially the same as that of FIG. 1 is obtained by forming the upper contact layer 26 .
- the graphene layer 23 is thickened by providing a level difference in the metallic catalyst layer 22 .
- a hard mask (not shown) is used to etch a part of the graphene separation layer 24 and its underlayer, i.e., the metallic catalyst layer 22 , as shown in FIG. 3A . That is, by performing over-etching for the metallic catalyst layer 22 after processing the graphene separation layer 24 , a level difference having a form of a graphene separation layer is formed on the surface of the catalyst layer 22 .
- the graphene layer 23 is grown by CVD.
- Graphene grows so as to embed the level differences in a catalyst. Therefore, it is possible to form graphene according to the height of a level difference. That is, by giving a level difference to the catalyst layer 22 on the interconnect layer 20 b , it is possible to thicken the graphene layer 23 . It is thereby possible to further reduce resistance of a portion of the interconnect layer 20 b.
- the contact layer insulating film 25 and the contact via 26 are formed.
- the third embodiment it is possible to thicken the graphene layer 23 by giving a level difference to the catalyst layer 22 on the interconnect layer 20 b having a wide width. It is therefore possible to further reduce resistance of a portion of the interconnect layer 20 b.
- FIGS. 4A to 4F are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a fourth embodiment. Note that the same portions as FIG. 1 are given the same reference numbers to omit the detailed description.
- the method of the fourth embodiment is to process a metallic catalyst layer by RIE, not to embed a metallic catalyst layer in an interconnect groove.
- the first contact layer insulating film 11 and the lower contact via 12 are formed on the Si substrate 10 .
- the catalyst underlayer 21 and the metallic catalyst layer 22 are then formed on the insulating film 11 , as shown in FIG. 4A .
- a film that functions as the graphene separation layer 24 is formed on the whole surface of the metallic catalyst layer 22 . Then, after the processes of lithography, RIE and the like, the graphene separation layer 24 is formed in a portion that functions as an interconnect portion in a narrow-width interconnect such as cell. Further, in a wide-width interconnect such as sense amplifier, the graphene separation layer 24 is formed in a space, where graphene is not formed, in a region that functions as an interconnect portion.
- a resist 28 is formed so as to cover only a wide-width interconnect portion to form a wide-width interconnect.
- the resist 28 and the separation layer 24 are used for a mask to process the metallic catalyst layer 22 and the catalyst underlayer 21 between an interconnect by RIE.
- the metallic catalyst layer 22 and the catalyst underlayer 21 remain only on a portion of the separation layer 24 when the width is narrow, while the metallic catalyst layer 22 and the catalyst underlayer 21 remain only on a portion of the resist 28 when the width is wide.
- the separation layer 24 in a narrow-width portion is eliminated and the resist 28 of a wide-width portion is peeling by ashing.
- the graphene layer 23 is formed by CVD or the like. At this time, since the side face of the metallic catalyst layer 22 is exposed, graphene is formed on the exposed side as well as the exposed surface of the catalyst layer 22 .
- gas containing a doping element may be added to material gas for purpose of doping into graphene. It is also possible to perform processing such as anneal under a doping material atmosphere after forming graphene for the same purpose.
- the fourth embodiment it is thus possible to obtain the same effect as the first and second embodiments and to form the graphene layer 23 on the side of the catalyst layer 22 . Therefore, it is possible to further reduce resistance of an interconnect layer.
- FIG. 5 is a cross-sectional view illustrating the process of manufacturing a semiconductor device according to a fifth embodiment. Note that the same portions as FIG. 1 are given the same reference numbers to omit the detailed description.
- the fifth embodiment is characterized in that a catalyst layer as well as graphene is separated into a plurality of pieces for a wide-width interconnect.
- the metallic catalyst layer 22 is formed to be separated into a plurality of pieces.
- a catalyst separation layer 29 is formed so as to separate the grooves 14 .
- the material of the separation layer 29 may be the same as that of the catalyst underlayer 21 .
- the metallic catalyst layer 22 which is embedded in the interconnect grooves 14 , is thereby separated into a plurality of fine lines. Thereafter, graphene grows only on the catalyst layer 22 by forming graphene. Therefore, the graphene layer 23 is separated into fine lines on the interconnect layer 20 b.
- the separated graphene layers function as a single interconnect, if the separation layer 29 is an electrical conductor. Further, if the catalyst underlayer 21 is an electrical conductor, the separated graphene layers function as a single interconnect. Even if both the catalyst underlayer 21 and the separation layer 29 are insulators, in the end portion (one end or both ends) in a longitudinal direction of an interconnect, the separated graphene layers can function as a single interconnect when the metallic catalyst layer 22 is connected.
- a material that separates the metallic catalyst layer 22 is a material that inhibits growth of graphene, not limited to a material of the catalyst underlayer 21 .
- While an chemical element for reducing the resistance of a graphene layer is added to the material gas of CVD in the embodiments, solid-phase diffusion by means of a material adjacent to a graphene layer may be used.
- a material containing a doping material for graphene may be used as a graphene separation layer.
- the doping material a material with which graphene can be doped and which does not relate to graphene growth is used.
- a material containing a doping material for graphene may be used.
- a material with which graphene can be doped and which is a catalyst for growing graphene is used.
- a catalyst underlayer as a barrier metal of a metallic catalyst layer is formed in the embodiments, a catalyst underlayer can be omitted when the diffusion from the metallic catalyst layer into a lower-layer contact does not matter.
- a catalyst layer does not need to be made of metal. It is desirable that a catalyst layer be conductive so that a plurality of graphene layers function as a single interconnect. However, a catalyst layer does not need to be conductive, if a graphene layer is connected only at a contact part or if a graphene separation layer is made conductive.
- FIGS. 7A and 7B show an example where a catalyst layer is not made of metal and a graphene separation layer is not conductive.
- FIG. 7A is a plan view and FIG. 7B is a cross-sectional view of FIG. 7A , taken along line A-A′.
- the plurality of graphene layers 23 function as a single interconnect by connecting the plurality of graphene layers 23 at the end portion.
- the contact via 12 and the plurality of graphene layers 23 shown in FIG. 1 can be connected without any problem, if the plurality of graphene layers 23 contact the catalyst underlayer 21 at the end portion.
- the element doped into the graphene layer is not always limited to Br, Cl and N; other elements can also be used. In addition, it is possible that one or more than one of these elements is doped.
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Abstract
Description
- This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2014-010252, filed Jan. 23, 2014, the entire contents of which are incorporated herein by reference.
- Embodiments described herein relate generally to a semiconductor device using graphene for interconnecting an LSI and a method of manufacturing the same.
- Recently, a graphene interconnect structure using graphene instead of metal has been attracting attention. Graphene, a novel carbon material in which graphite is made extremely thin, exhibits quantized (ballistic) conduction properties in the same way that a carbon nanotube does.
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FIG. 1 is a cross-sectional view illustrating the schematic structure of a semiconductor device according to a first embodiment; -
FIGS. 2A to 2E are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a second embodiment; -
FIGS. 3A and 3B are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a third embodiment; -
FIGS. 4A to 4F are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a fourth embodiment; -
FIG. 5 is a cross-sectional view illustrating the schematic structure of a semiconductor device according to a fifth embodiment; -
FIG. 6 is a graph illustrating the relationship between interconnect width and resistance of graphene; and -
FIGS. 7A and 7B are plan and a sectional view to explain the example of the modification. - In general, according to one embodiment, there is provided a semiconductor device using graphene, comprising a catalyst layer formed on or in a substrate along with an interconnect pattern and a graphene layer formed on the catalyst layer. The graphene layer is arranged parallel to a narrower linewidth than the width of the interconnect pattern.
- Since graphene exhibits quantized conduction properties as mentioned above, it can be used as an interconnect having ultimately low resistance instead of a metallic interconnect and is advantageous with respect to electrical conduction in a long-distance interconnect. Also, graphene has excellent consistency for a process of forming a device interconnect, since the structure of graphene itself is an extremely thin film and graphene can be formed by a CVD method.
- In an interconnect structure using graphene, while it is possible to realize a lower-resistance interconnect having a narrow linewidth than conventional metal, there is a case where resistance is higher in a wide-linewidth interconnect than conventional metal. Also, it is known that doping other elements is effective as a method for further realizing low resistance in a graphene interconnect structure. However, it is difficult to introduce elements sufficiently into a graphene layer when the width of an interconnect is wide. In a graphene interconnect structure, it is therefore important how doping is carried out when the width of an interconnect is wide.
- As shown in
FIG. 6 , the resistance of Cu, which is normal interconnect metal, increases as the interconnect becomes narrower, while the resistance of graphene does not. Note in the figure that “SW-GNR” refers to a single-layer graphene and “SW-CNT” a single-layer carbon nanotube. - That is, the resistance remains almost constant in a fine interconnect width as a result of the quantum effect, regardless of linewidth. Also, the resistance of graphene is by far lower than that of Cu in a region having a width of approximately 10 nm or less because of quantized conduction properties. This reveals that the graphene is effective in a narrow-linewidth interconnect and not effective in a wide-linewidth interconnect.
- The purpose of the present embodiment is to reduce interconnect resistance by separating graphene into a plurality of pieces having a narrow linewidth. That is, although by separating graphene into a plurality of pieces having a width of tens of nm, the resistance of each piece of graphene gets slightly higher than that of graphene having the original width, the total resistance of the plurality of pieces gets substantially lower than that of graphene having the original width by connecting a plurality of pieces in parallel. The purpose of the present embodiment is to thereby reduce the resistance of a graphene interconnect.
- Semiconductor devices according to embodiments will be hereinafter described with reference to the accompanying drawings.
-
FIG. 1 is a cross-sectional view illustrating the schematic structure of a semiconductor device according to a first embodiment. - A plurality of
interconnect layers 20 are formed on a substrate. A part of theinterconnect layers 20 are connected to a lower semiconductor element and an upper interconnect layer through a contact via. The first embodiment has a novel LSI interconnect structure using graphene to the material of theinterconnect layers 20 and is characterized in that graphene is separated particularly in a wide-width interconnect. In the following, a detailed description will be given. - A first contact layer
insulating film 11 is formed on aSi substrate 10, on which semiconductor elements such as transistor and capacitor are formed. A lower contact via 12, which is configured to connect a lower-layer semiconductor element and an upper-layer interconnect layer, is embedded and formed in theinsulating film 11. An interconnectlayer insulating film 13 is formed on theinsulating film 11, on which the contact via 12 is formed. A plurality ofinterconnect grooves 14 are formed in theinsulating film 13. - The structure of forming the contact
layer insulating film 11 and the contact via 12 on theSi substrate 10 is defined as a substrate. Also, it is possible to define a substrate including the interconnectlayer insulating film 13 on the contactlayer insulating film 11. - A
catalyst underlayer 21, which is configured to promote uniform growth of a graphene layer, is formed on the bottom face and the side face of theinterconnect grooves 14. Further, ametallic catalyst layer 22, which is configured to grow a graphene layer, is formed on thecatalyst layer 21 so as to embed theinterconnect grooves 14. Agraphene layer 23, which functions as an electrically conductive layer, is formed on themetallic catalyst layer 22. Theinterconnect layers 20 consist of thecatalyst underlayer 21, themetallic catalyst layer 22 and thegraphene layer 23. - The
graphene layer 23 is formed on the whole surface of thecatalyst layer 22 in aninterconnect layer 20 a, which has a narrow linewidth (for example, 10 nm or less). Thegraphene layer 23 is separated into a plurality of layers in aninterconnect layer 20 b, which has a wide linewidth. That is, agraphene separation layer 24 is formed on thecatalyst layer 22 to separate thegraphene layer 23 to a width of, for example, 10 nm or less. Note that while theinterconnect layer 20 b is connected to the contact via 12 inFIG. 1 , it may also be possible that theinterconnect layer 20 a is connected to the contact via 12. - Note that a graphene layer is a layer where a plurality of graphene sheets are laminated in a direction non-parallel to the surface of a substrate. In
FIG. 1 , a plurality of graphene sheets are laminated in a vertical direction to the surface of themetallic catalyst layer 22. Such graphene layers are arranged side by side in a parallel direction to the surface of themetallic catalyst layer 22. - A second contact
layer insulating film 25 is formed on the interconnectlayer insulating film 13, on which theinterconnect layers 20 are formed. A contact via 26 is embedded and formed in theinsulating film 25. The contact via 26 is configured to contact thegraphene layer 23 of theinterconnect layer 20 a. Note that the contact via 26 may be formed so as to contact theinterconnect layer 20 b. - The
catalyst underlayer 21 is an auxiliary film for promoting uniform growth of thegraphene layer 23. Also, thecatalyst underlayer 21 plays a role in preventing diffusion into the insulating film and the underlayer contact from themetallic catalyst layer 22. The typical materials of thecatalyst underlayer 21 include Ta, Ti, Ru, W and Al. Also, it is possible to use the nitride and oxide of these films and a laminating material containing these films. - The
metallic catalyst layer 22 is a layer necessary for growing graphene. It is preferable that any of single metals, Co, Ni, Fe, Ru and Cu is used for the material of themetallic catalyst layer 22. It is also preferable that alloy containing at least any of them or carbide of them is used for the material of themetallic catalyst layer 22. It is desirable that thecatalyst layer 22 of graphene be a continuous film. It is therefore necessary that thecatalyst layer 22 be formed to have a thickness of at least 0.5 nm to be a continuous film. Graphene itself cannot grow well in a state where thecatalyst layer 22 is diffused and microparticulated. Further graphene layer might be formed in discontinuity. Accordingly, it is necessary that thecatalyst 22 be formed to have a thickness enough to be a continuous film, in order to form uniform continuous graphene layers. - The
graphene layer 23 is a layer on which novel carbon materials having extremely thin graphite are laminated. Also, thegraphene layer 23 can be used instead of a metallic interconnect to realize an interconnect having ultimately low resistance as a result of quantized conduction. In the structure of the first embodiment, graphene functioning as an electrically conductive layer is formed as a laminated layer. - The
graphene separation layer 24 is formed so as to form a plural pieces of graphene narrower than an interconnect width in a longitudinal direction of the interconnect. The materials of thegraphene separation layer 24 include a hardmask material and inhibit graphene growth on the surface of theseparation layer 24. For example, it is possible to use Ta, Ti, Ru, W, Al, Si and the like, and nitride or oxide of material thereof. A low-resistance material can be used for theseparation layer 24 to use it as a part of the electrically conductive layer. Further, a material that functions as dopant can be used to dope other elements into graphene. - It is also possible that a diffusion barrier layer (not shown) such as SiN is formed so as to cover the above-mentioned interconnect structure.
- In such a structure, it is possible to reduce an interconnect resistance by finely separating and forming the
graphene layer 23, even when the interconnect layer has a wide width. Also, such a structure allows chemical elements to be easily introduced to each of the separated graphene layers, which further reduces resistance of the graphene layer. - That is, the structure in the first embodiment is the same as a conventional graphene interconnect structure when the linewidth is narrow, and narrow-width graphene is formed in parallel when the linewidth is wide. This realizes a graphene interconnect structure suitable for doping while exploiting the quantized conduction of graphene. Therefore, it is possible to reduce interconnect resistance and contribute to improving the performance of a semiconductor device. With a wide-width interconnect, it is also possible to increase the ratio of sidewalls by forming a narrow-width graphene in parallel as an electrically conductive layer. It is thereby possible to easily dope other elements into the graphene.
- Next, a method of manufacturing the semiconductor device of the first embodiment will be described as a second embodiment.
-
FIGS. 2A to 2E are cross-sectional views illustrating the process of manufacturing the semiconductor device according to the second embodiment. Note that while the position of the contact via is different from that ofFIG. 1 , it is possible that the position is the same as inFIG. 1 . - To begin with, as shown in
FIG. 2A , the first contactlayer insulating film 11 such as TEOS is formed on theSi substrate 10, on which semiconductor elements such as transistor and capacitor are formed. Also, the lower contact via 12, which is configured to connect the semiconductor element of a lower layer and the interconnect layer of an upper layer, is embedded and formed in the insulatingfilm 11. A single metal such as W, Cu and Al is used for conductive material as the contact via 12. - Next, as shown in
FIG. 2B , the interconnectlayer insulating film 13 such as SiO2 film and SIOC film is formed on the insulatingfilm 11. If a sufficient selection ratio between the contactlayer insulating film 11 and the interconnectlayer insulating layer 13 cannot be obtained, a stopper layer such as SiCN can be formed on the upper face of the contactlayer insulating film 11. - Then, the plurality of
interconnect grooves 14, which are configured to form an interconnect layer, are formed in the interconnectlayer insulating layer 13 by RIE or the like. Thecatalyst underlayer 21, which functions as an auxiliary film for facilitating preparation of a graphene layer, is formed on the bottom face and the side face of each of the plurality ofinterconnect grooves 14. Further, themetallic catalyst layer 22 for growing a graphene layer is formed on thecatalyst underlayer 21. Note in the figure that the left side corresponds to theinterconnect layer 20 a having a narrow linewidth and the right side corresponds to theinterconnect layer 20 b having a wide linewidth. An underlayer material and a catalyst material are as mentioned above. The surface is then flattened after a CMP process. - Subsequently, as shown in
FIG. 2C , a fine line that functions as thegraphene separation layer 24 is formed on a portion that functions as a wide-linewidth interconnect portion. For example, a separation layer material film is formed on the whole surface, and a resist is formed thereon. Then, the plurality of graphene separation layers 24 are formed by photolithography and RIE so that the width of the exposed portion of themetallic catalyst layer 22 is narrower than a predetermined interconnect width. The materials of theseparation layer 24 are as described above. - A predetermined interconnect width is defined as follows. When a linewidth is made less than that of a narrow interconnect by dividing a wide-linewidth interconnect, processing is not possible. Therefore, it is necessary to make the width of a divided graphene wider than a processable narrow interconnect width. The width of a wide interconnect is three times wider than that of a narrow interconnect, since at least two pieces of graphene having a width wider than the width of the narrow interconnect need to be arranged. Therefore, a dividable interconnect is an interconnect three times wider than the narrowest interconnect in the same layer. That is, when the smallest width that can be formed by fine processing is 10 nm, a predetermined interconnect width is 30 nm. Note that a predetermined interconnect width can be further reduced when the smallest width decreases.
- Thereafter, as shown in
FIG. 2D , thegraphene layer 23, which functions as an electrical conductive layer, is formed. Thegraphene layer 23 is formed by a CVD method. Hydrocarbon series gas such as methane and acetylene or mixed gas thereof is used for the carbon source of a CVD method, and hydrogen and rare gas are used for carrier gas. Thegraphene layer 23 has a feature of being formed only on thecatalyst layer 22, which is a continuous layer, not on the surface of thegraphene separation layer 24. - At this time, it is possible to add gas containing a doping element into material gas for purpose of doping into graphene. It is also possible to perform processing such as anneal under a doping material atmosphere for the same purpose. The elements of
groups 14 to 17 are used for doping material; N, Cl, Br and a reactant containing them are used. There is also a case where a metal such as Fe is included. - Then, as shown in
FIG. 2E , after forming the second contactlayer insulating film 25 such as TEOS, the structure substantially the same as that ofFIG. 1 is obtained by forming theupper contact layer 26. - Thus, according to the second embodiment, it is possible to form in parallel the plurality of graphene layers having a narrow linewidth in the
interconnect layer 20 b having a wide linewidth, by forming thegraphene separation layer 24 for theinterconnect layer 20 b having a wide linewidth. It is therefore possible to reduce the resistance of theinterconnect layer 20 b. - Also, by adding N, Cl, Br and the like, which contribute to reducing resistance of graphene, to material gas in CVD for graphene growth, it is possible to dope these elements to the
graphene layer 23. Since doping is conducted for thegraphene layer 23 in a lateral direction, it is impossible to dope into the inside effectively when graphene is wide. In the second embodiment, since the width of each of the graphene layers becomes smaller by separating graphene into a plurality of pieces, it is possible to dope into thegraphene layer 23 effectively. That is, it is possible to further reduce resistance of graphene by doping. - In the third embodiment, the
graphene layer 23 is thickened by providing a level difference in themetallic catalyst layer 22. - In the process shown in
FIG. 2C , a hard mask (not shown) is used to etch a part of thegraphene separation layer 24 and its underlayer, i.e., themetallic catalyst layer 22, as shown inFIG. 3A . That is, by performing over-etching for themetallic catalyst layer 22 after processing thegraphene separation layer 24, a level difference having a form of a graphene separation layer is formed on the surface of thecatalyst layer 22. - Next, as shown in
FIG. 3B , thegraphene layer 23 is grown by CVD. Graphene grows so as to embed the level differences in a catalyst. Therefore, it is possible to form graphene according to the height of a level difference. That is, by giving a level difference to thecatalyst layer 22 on theinterconnect layer 20 b, it is possible to thicken thegraphene layer 23. It is thereby possible to further reduce resistance of a portion of theinterconnect layer 20 b. - After forming the
graphene layer 23, as with the second embodiment, the contactlayer insulating film 25 and the contact via 26 are formed. - Thus, in the third embodiment, it is possible to thicken the
graphene layer 23 by giving a level difference to thecatalyst layer 22 on theinterconnect layer 20 b having a wide width. It is therefore possible to further reduce resistance of a portion of theinterconnect layer 20 b. -
FIGS. 4A to 4F are cross-sectional views illustrating the process of manufacturing a semiconductor device according to a fourth embodiment. Note that the same portions asFIG. 1 are given the same reference numbers to omit the detailed description. - The method of the fourth embodiment is to process a metallic catalyst layer by RIE, not to embed a metallic catalyst layer in an interconnect groove.
- First of all, as with
FIG. 2A , the first contactlayer insulating film 11 and the lower contact via 12 are formed on theSi substrate 10. Thecatalyst underlayer 21 and themetallic catalyst layer 22 are then formed on the insulatingfilm 11, as shown inFIG. 4A . - Next, as shown in
FIG. 4B , a film that functions as thegraphene separation layer 24 is formed on the whole surface of themetallic catalyst layer 22. Then, after the processes of lithography, RIE and the like, thegraphene separation layer 24 is formed in a portion that functions as an interconnect portion in a narrow-width interconnect such as cell. Further, in a wide-width interconnect such as sense amplifier, thegraphene separation layer 24 is formed in a space, where graphene is not formed, in a region that functions as an interconnect portion. - Subsequently, as shown in
FIG. 4C , a resist 28 is formed so as to cover only a wide-width interconnect portion to form a wide-width interconnect. - Then, as shown in
FIG. 4D , the resist 28 and theseparation layer 24 are used for a mask to process themetallic catalyst layer 22 and thecatalyst underlayer 21 between an interconnect by RIE. At this time, themetallic catalyst layer 22 and thecatalyst underlayer 21 remain only on a portion of theseparation layer 24 when the width is narrow, while themetallic catalyst layer 22 and thecatalyst underlayer 21 remain only on a portion of the resist 28 when the width is wide. - After processing the
catalyst layer 22 and theunderlayer 21, as shown inFIG. 4E , theseparation layer 24 in a narrow-width portion is eliminated and the resist 28 of a wide-width portion is peeling by ashing. - Next, as shown in
FIG. 4F , thegraphene layer 23 is formed by CVD or the like. At this time, since the side face of themetallic catalyst layer 22 is exposed, graphene is formed on the exposed side as well as the exposed surface of thecatalyst layer 22. As with the third embodiment, gas containing a doping element may be added to material gas for purpose of doping into graphene. It is also possible to perform processing such as anneal under a doping material atmosphere after forming graphene for the same purpose. - Thereafter, a second contact layer insulating film, an upper contact via and the like are formed.
- According to the fourth embodiment, it is thus possible to obtain the same effect as the first and second embodiments and to form the
graphene layer 23 on the side of thecatalyst layer 22. Therefore, it is possible to further reduce resistance of an interconnect layer. -
FIG. 5 is a cross-sectional view illustrating the process of manufacturing a semiconductor device according to a fifth embodiment. Note that the same portions asFIG. 1 are given the same reference numbers to omit the detailed description. - The fifth embodiment is characterized in that a catalyst layer as well as graphene is separated into a plurality of pieces for a wide-width interconnect.
- As shown
FIG. 5 , themetallic catalyst layer 22 is formed to be separated into a plurality of pieces. In this example, after forming thecatalyst underlayer 21 on the bottom face and the side face of theinterconnect grooves 14 and then embedding and forming themetallic catalyst layer 22, acatalyst separation layer 29 is formed so as to separate thegrooves 14. The material of theseparation layer 29 may be the same as that of thecatalyst underlayer 21. Themetallic catalyst layer 22, which is embedded in theinterconnect grooves 14, is thereby separated into a plurality of fine lines. Thereafter, graphene grows only on thecatalyst layer 22 by forming graphene. Therefore, thegraphene layer 23 is separated into fine lines on theinterconnect layer 20 b. - Note that when the
graphene layer 23 is separated into a plurality of pieces, the separated graphene layers function as a single interconnect, if theseparation layer 29 is an electrical conductor. Further, if thecatalyst underlayer 21 is an electrical conductor, the separated graphene layers function as a single interconnect. Even if both thecatalyst underlayer 21 and theseparation layer 29 are insulators, in the end portion (one end or both ends) in a longitudinal direction of an interconnect, the separated graphene layers can function as a single interconnect when themetallic catalyst layer 22 is connected. - Also, the same effect can be obtained, if a material that separates the
metallic catalyst layer 22 is a material that inhibits growth of graphene, not limited to a material of thecatalyst underlayer 21. - Even under such a structure, it is possible to finely separate and form the
graphene layer 23 in a wide-width interconnect layer and thereby to reduce interconnect resistance. Therefore, the same effect as the first embodiment can be obtained. - (Example of Deformation)
- Note that the present invention is not limited to each of the embodiments described above.
- While an chemical element for reducing the resistance of a graphene layer is added to the material gas of CVD in the embodiments, solid-phase diffusion by means of a material adjacent to a graphene layer may be used. For example, a material containing a doping material for graphene may be used as a graphene separation layer. As the doping material, a material with which graphene can be doped and which does not relate to graphene growth is used. By using the material containing the doping material as the graphene separation layer, it is possible to cause solid-phase diffusion of the dopant from the graphene separation layer into the graphene.
- Also, a material containing a doping material for graphene may be used. For the doping material, a material with which graphene can be doped and which is a catalyst for growing graphene is used. By using the material containing the doping material as a graphene separation layer, it is possible to cause solid-phase diffusion of dopant from the metallic catalyst layer into the graphene.
- Further, while a catalyst underlayer as a barrier metal of a metallic catalyst layer is formed in the embodiments, a catalyst underlayer can be omitted when the diffusion from the metallic catalyst layer into a lower-layer contact does not matter. In addition, a catalyst layer does not need to be made of metal. It is desirable that a catalyst layer be conductive so that a plurality of graphene layers function as a single interconnect. However, a catalyst layer does not need to be conductive, if a graphene layer is connected only at a contact part or if a graphene separation layer is made conductive.
-
FIGS. 7A and 7B show an example where a catalyst layer is not made of metal and a graphene separation layer is not conductive.FIG. 7A is a plan view andFIG. 7B is a cross-sectional view ofFIG. 7A , taken along line A-A′. In this case, it is possible to make the plurality of graphene layers 23 function as a single interconnect by connecting the plurality of graphene layers 23 at the end portion. In addition, the contact via 12 and the plurality of graphene layers 23 shown inFIG. 1 can be connected without any problem, if the plurality of graphene layers 23 contact thecatalyst underlayer 21 at the end portion. - Furthermore, the element doped into the graphene layer is not always limited to Br, Cl and N; other elements can also be used. In addition, it is possible that one or more than one of these elements is doped.
- While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
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| US10269706B2 (en) * | 2016-07-26 | 2019-04-23 | Taiwan Semiconductor Manufacturing Co., Ltd. | Semiconductor device and manufacturing method thereof |
| US12132000B2 (en) * | 2021-08-28 | 2024-10-29 | Taiwan Semiconductor Manufacturing Company, Ltd. | Semiconductor device structure and methods of forming the same |
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| US10170426B2 (en) * | 2015-03-18 | 2019-01-01 | Fujitsu Limited | Manufacturing method of wiring structure and wiring structure |
| JP7611814B2 (en) | 2018-08-11 | 2025-01-10 | アプライド マテリアルズ インコーポレイテッド | Graphene Diffusion Barrier |
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| JP2013518438A (en) | 2010-01-25 | 2013-05-20 | ボード オブ トラスティーズ オブ ザ レランド スタンフォード ジュニア ユニバーシティ | Connected nanostructures and methods therefor |
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| US11296026B2 (en) | 2016-07-26 | 2022-04-05 | Taiwan Semiconductor Manufacturing Co., Ltd. | Semiconductor device and manufacturing method thereof |
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