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Abstract—This paper presents challenges encountered in the successful gap fill of TSVs of 3μm entrant CD and 50um
fabrication of high aspect ratio (AR) via middle, through-silicon depth with existing PVD Ta barrier and Cu seed metallization
vias (TSVs), of 3 µm top entrant critical dimension and 50 µm processes.
depth. Higher AR TSV integration is explored due to the lower
stress and copper pumping influence of TSVs observed in adja- 3x50μm TSV introduced several processing challenges over
cent CMOS devices. The key process improvements demonstrated the current 6μm standard TSV. Since the TSV depth is main-
in this paper include 3 µm TSV etch, dielectric liner coverage, tained at 50μm, the higher AR causes difficulties in achieving
metal barrier and seed layer coverage, and copper electroplating. continuous TSV metallization and void free bottom-up filling.
Index Terms—TSV, high aspect ratio, etch, electroplating, These challenges were overcome through several experimen-
KOZ, 3D. tal iterations using a test vehicle with < 0.1% TSV density,
which will be described in the following sections.
I. I NTRODUCTION Cu pumping of the TSVs is another major reliability con-
cern. It is determined by the step height of the TSV Cu
HE USE of 3D stacking technology addresses the sus-
T tainability of higher bandwidth and lower latency by
maintaining both signal and power integrity of the dies when
compared to the field, measured after the TSV CMP step
(or potentially after BEOL processing). As Cu volume is
directly related to the extent of Cu pumping, TSV CD
stacked by Through-Silicon Vias (TSVs); thermal mechani- is one of the key variables that can be adjusted to mini-
cal and electrical impact on both dies and front end devices mize Cu pumping, and also reduce the overall stress applied
are key criteria in determining AR of the integrated TSVs. to the silicon. In the current example, a reduction in CD
The stress impact of TSVs on front end devices, NFET and from 6μm to 3μm results in a Cu volume decrease of
PFET, is addressed in the industry when integrating TSVs approximately 75%.
into a manufacturing baseline flow. Stress builds up in Si and
copper (Cu) during the additional thermal cycles in back end
of line (BEOL) as a coefficient of thermal expansion (CTE) II. TSV M ODULE
mismatch exists between Cu in the TSV and the silicon A. TSV Formation and Metrology
substrate. This stress build up may propagate in the silicon Etch patterning to define the overall TSV layout was done
and the BEOL layers, impacting the performance of transis- using a standard photoresist at roughly 4μm thickness. This
tors through mobility shifts as well as fracturing of the top photoresist needs to provide sufficient resist margins during
ULK and metal layers with TSV Cu pumping. TCAD sim- the TSV etch and prevent any erosion of the underlying hard-
ulations were performed to find an effective TSV diameter mask (HM) or middle of line (MOL) layer.
that minimized the stress gradient between the TSV metal- The TSV etch profile was developed on the Lam
lization and oxide dielectric interface; 3μm diameter TSV Syndion C R
platform; the etching of the high AR TSV profile
resulted in the minimum stress gradient between the Ta and Cu was done using transformer coupled plasma. The DRIE (Deep
interface. Reduced stress was observed with the 3um CD, Reactive Ion Etch) was done using the Rapidly Alternating
which allows for both increased density of TSVs, as well as Process (RAP) of etch and deposition, based on the BOSCH
a lower Keep Out Zone (KOZ) for placement of front end method. The immediate result, when using the best known
devices in the vicinity of the TSVs. This work demonstrates method (BKM) process for the larger 6μm diameter TSV with
Manuscript received June 22, 2015; accepted July 28, 2015. Date of this higher aspect ratio via, showed that there were consider-
publication October 1, 2015; date of current version November 13, 2015. able barriers to its immediate use. Challenges to overcome
(Corresponding author: Dingyou Zhang). included etch stop, via striations, mask undercut, resist bud-
D. Zhang, D. Smith, G. Kumarapuram, R. Giridharan, S. Kakita,
M. A. Rabie, P. Feng, and L. England are with GlobalFoundries, Malta, get, and HM erosion. These issues are highlighted in the cross
NY 12020 USA (e-mail: dingyou.zhang@globalfoundries.com). sections shown in Fig. 1.
H. Edmundson is with Nanometrics, Hillsboro, OR 97124 USA. To establish a baseline etch process for 3μm TSV, the
Color versions of one or more of the figures in this paper are available
online at http://ieeexplore.ieee.org. main factor in the evolution of the sidewall profile improve-
Digital Object Identifier 10.1109/TSM.2015.2485079 ment (targeting a straight profile) was optimizing the RAP
0894-6507 c 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
ZHANG et al.: PROCESS DEVELOPMENT AND OPTIMIZATION FOR 3 µm HIGH AR VIA-MIDDLE TSVs AT WAFER LEVEL 455
Fig. 2. Series of etch depths from 3:1 to 20:1 AR with 3μm diameter opening
using the 3μm BKM recipe. A gradual increase in bowing in the top entrant
of the TSV with increased depth was observed. Also notice the increase in
resist consumption with increased depth.
TABLE I
DOE FOR 3μm TSV P OST E TCH R ESIST R ETAINING I MPROVEMENT
Fig. 1. Cross section images of the 3x50μm TSV at the top, middle, and
bottom areas highlighting initial defects seen using the existing BKM recipes
for larger TSV diameters.
TABLE II
DOE FOR 3μm TSV P OST E TCH N OTCH E NTRANCE AND D EPTH
U NIFORMITY I MPROVEMENT
Fig. 4. Cross sections showing 3x50μm deep TSV bottom with (a) the
presence of a Si fin defect and (b) lack of Si fin defects due to use of lower
BMD Si.
Fig. 8. Cross section of TSV post TSV CMP showing successful landing
on hardmask with no erosion.
TABLE III
S UMMARY OF M ECHANICAL S IMULATION R ESULTS
IV. C ONCLUSION
Using a 3x50μm TSV test vehicle, we have successfully
demonstrated key processing aspects of a high AR TSV to
Fig. 9. Mechanical simulation results for (a) 6x55μm TSV and (b) 3x50μm support further scaling from the current POR of 6x55μm TSV
TSV structures.
dimensions. Although there were several processing challenges
to overcome, the existing 3D TSV toolset was able to be
used. Results of this series of evaluations showed no negative
impacts of the TSV diameter scaling. The following points
highlight key enabling adjustments that were made:
• A higher bias voltage was used during both clear and
deposition phases, an additional C4 F8 gas flow was used
during etch phase, and a longer pre-coat time was used
after HM opening for 3x50μm TSV etch for the consid-
eration of photoresist retaining, notch entrance, and depth
uniformity improvement.
• The TSV dielectric liner field thickness was reduced
to prevent pinch-off at the opening during ECP filling.
Even with the reduced thickness, there was good side-
wall coverage at the TSV bottom. An alternative ALD
Fig. 10. Cu pumping simulation results and schematic comparing 6x55μm dielectric liner process was also developed for 3x50μm
and 3x50μm TSV structures. TSV, which allows for a thinner film due to its conformal
coverage.
translates into a low KOZ for improved layout capabilities. • Barrier and liner metal layer field thicknesses were
These TCAD simulations for a 6x55μm TSV structure predict increased (i.e., longer deposition time) to compensate
negligible effect on threshold voltages and drain currents for for reduced PVD sidewall coverage at the bottom of
20nm devices, and match well with measured transistor perfor- high aspect ratio features. Overall sidewall thickness was
mance values [6]. The 3x50μm TSV structure is predicted to lower, however.
have a similarly negligible impact on device performance, and • No change was made to the ECP filling process. Current
the final transistor characterization measurements to validate delivery was sufficient with the thinner barrier and seed
are ongoing. layers.
460 IEEE TRANSACTIONS ON SEMICONDUCTOR MANUFACTURING, VOL. 28, NO. 4, NOVEMBER 2015
•
CMP processing parameters were adjusted to compensate Gopal Kumarapuram received the B.E. degree in
for new dielectric and barrier/seed layer thicknesses on electronics and telecommunications from Mumbai
University in 2009 and the M.S. degree in electrical
the wafer surface. engineering from Boston University in 2012.
Mechanical stress simulations were also completed that He spent the summer of 2010 with Stanford
predict a reduction in Cu pumping and stress applied to University, pursuing courses in macroeconomics
and international finance. From 2011 to 2012,
the surrounding transistors with a shift to 3μm diameter he was a Research Assistant with the Photonics
TSV. The replacement of Ta barrier metal with Ti barrier metal Center, Boston University, focusing on develop-
was included in the simulations, and results suggest a larger ing a digital processing system. Since 2012, he
has been a Process Engineer of Etch Module with
severity of Cu pumping, but lower propensity for sidewall GlobalFoundries, Malta, NY, USA. He has been developing the high aspect
delamination. This combination of increased and decreased ratio etch for the through silicon via process for different nodes of the
benefits will require further investigation to determine if Ti is technology. He also works on BEOL etch specializing in aluminum etch.
a more appropriate barrier metal than Ta.
Rudy Giridharan, photograph and biography not available at the time of
ACKNOWLEDGMENT publication.