Focus error reduction by photo-resist planarization in via-first dual damascene process

In order to reduce the focus error for the stacked mask process (SMAP) used in Cu/low-k dual damascene (DD) interconnect, a planarization technology of the under layer film by CMP was developed. Photo-resist was used for the under layer film. CMP slurry with resin abrasive was investigated for the photo-resist planarization. The slurry showed better planarity, lower risk to particle residue, and high selectivity to SiO/sub 2/ film. These advantages are attributable to the effects of the particle size and the material characteristics similar to photo-resist. Furthermore, it was found that it is effective for a higher CMP rate to turn the platen and head with lower rotational speed. Using the photo-resist planarization technology, application to via first DD process was investigated. It became clear that focus error reduction of 0.1 /spl mu/m is confirmed compared with conventional SMAP. The depth of focus (DOF) margin loss due to resist thickness variation caused by via density variation is completely canceled by photo-resist planarization.