Interconnect Structure With Self-Forming Barrier for Lower RC Delay

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Solution Overview

Problem

As feature sizes in semiconductor devices decrease, the distance between metal features reduces, leading to increased resistance and parasitic capacitance, which in turn causes larger resistance-capacitance (RC) time delay for integrated chips.

Innovation Solution

A method for manufacturing semiconductor devices involves forming a sacrificial stack on a semiconductor substrate, followed by the formation of a metal material layer that includes a first metal with a lower reduction potential than a second metal. The metal material layer is annealed to form a self-forming barrier layer, and a self-forming etch stop layer is formed through oxidation of the first metal, reducing the resistance and capacitance of the semiconductor device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If feature sizes are decreased to improve integration density, then integration density is improved, but resistance and parasitic capacitance increase

Engineering Contradiction:
Improveintegration densityVSAvoidresistance and parasitic capacitance
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent applies different materials with different dielectric constants to different regions of the interconnect structure. Specifically, a first dielectric material with a first dielectric constant is used in a first region, while a second dielectric material with a second dielectric constant (lower than the first) is used in a second region. This local differentiation allows the structure to maintain high integration density while reducing parasitic capacitance in critical areas where metal features are closely spaced.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes the dielectric constant parameter of the insulating material by using two different dielectric materials with different dielectric constants. The first dielectric material has a higher dielectric constant for better signal coupling and impedance control, while the second dielectric material has a lower dielectric constant to reduce parasitic capacitance. This parameter change strategy enables simultaneous optimization of both integration density and electrical performance.

Inventive Principle:
Principle #35Parameter changes

2Quantity of substance

If distance between metal features is reduced to improve integration density, then integration density is improved, but RC time delay increases

Engineering Contradiction:
Improveintegration densityVSAvoidRC time delay
Core Design Contradiction:
Quantity of substanceVSLoss of time

Solution Approach 1:

The patent implements local quality by assigning different dielectric materials to different spatial regions. The first dielectric material is placed in regions where signal integrity and impedance control are critical, while the second dielectric material with lower dielectric constant is placed in regions where parasitic capacitance contributes most to RC delay. This spatial differentiation reduces overall RC time delay while maintaining compact feature spacing for high integration density.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent modifies the dielectric constant parameter across different regions of the interconnect structure. By using a second dielectric material with a lower dielectric constant in specific regions, the parasitic capacitance is reduced, which directly decreases the RC time delay. This parameter change enables faster signal propagation while maintaining the reduced feature sizes necessary for high integration density.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively reduces the resistance and capacitance of semiconductor devices, thereby minimizing RC time delay and enhancing the integration density of electronic components.

Implementation Method 1

a self-forming etch stop layer is formed through oxidation of the first metal

Methodology Applied
Scientific EffectOxidation: Oxidation

Implementation Method 2

The metal material layer is annealed to form a self-forming barrier layer

Methodology Applied
Scientific EffectAnnealing: Annealing

Data Source

PatentUS20250105140A1Semiconductor device including interconnect structure and method for manufacturing the same
Publication Date: 2025.03.27 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD
  • US20250105140A1 patent drawing
  • US20250105140A1 patent drawing
  • US20250105140A1 patent drawing

AI summary

A method for manufacturing a semiconductor device includes: forming a plurality of sacrificial stack portions on a semiconductor substrate, the sacrificial stack portions being spaced apart from each other; forming a metal material layer to cover the sacrificial stack portions, the metal material layer including a first metal and a second metal different from the first metal, the first metal having a reduction potential lower than that of the second metal; and annealing the metal material layer to form a self-forming barrier layer conformally covering the sacrificial stack portions, the self-forming barrier layer including a metal oxide, a metal silicide, or a combination thereof formed from the first metal by annealing.