In this paper, physical and electrical results of full wafer direct Cu plating of 2×40 µm TSVs with thin Ru seed are presented. Physical vapor deposition of about 100 nm Cu in the field is shown to improve plating non-uniformity across the structured wafer. TSV plating using Atotech's TSV III chemistry results in bottom-up growth with strong TSV sidewall suppression and void free TSV fill. Early results for in-line electrical test and voltage ramp dielectric breakdown reliability testing are discussed.
INTRODUCTIONHigh-aspect ratio TSVs are desirable for 3D-IC integration with increased device density and smaller keepout zones. Good step coverage of thin film barrier and seed for such TSVs becomes increasingly challenging when TSVs exceed a depth to diameter ratio of 15:1. Traditional physical vapor deposition (PVD) techniques fail to yield uniform coverage. Hence chemical vapor deposition (CVD) or atomic layer deposition (ALD) based barrier and seed layers have been adopted. A conducting seed is a prerequisite for the electrodeposition of Cu, which is so far the preferred method for TSV metallization. Ru has been widely considered as a seed layer for Cu electrodeposition in high aspect ratio BEOL and 3DI structures [1, 2], with added advantage due to its barrier properties. To reduce cost of ownership, a thin Ru seed layer is desirable, which in turn results in an increased challenge to Cu electrodeposition due to the higher electrical resistance of the thin Ru layer.In this report, a study of electroplating high aspect ratio TSVs (depth to diameter aspect ratio of 20:1) with Ru seed layer on 300 mm wafers is presented. A field-only PVD copper film of optimized thickness is used to demonstrate void-free bottom-up TSV filling, mitigating the terminal effect in plating across the wafer. This study also presents TSV in-line electrical test and early reliability results.