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A physicochemical model for electroplating copper in through-silicon vias (TSVs) is proposed to investigate the filling mechanism.
Finite element method (FEM) and multifrontal massively parallel sparse direct solver (MUMPS) are employed to solve the numerical
model. The motion of the fluid/solid interface (electrolyte/metal interface) is tracking using the Arbitrary Lagrange-Eulerian (ALE)
method. Compared to other models, the diffusion, adsorption, desorption and incorporation of the additives (accelerator and
suppressor) and ions (cupric ion and chloride ion) are included in this model. Simultaneously, the deactivation of the accelerator and
the process parameters for copper deposition are also considered in the model. Numerical simulations are performed for filling the
40 m 140 m blind vias. The , V, 8, and extreme bottom-up filling models are achieved by verifying the component
of plating baths. A good match is achieved qualitatively between the simulated profiles and the real-world filling experiments.
2015 The Electrochemical Society. [DOI: 10.1149/2.0671510jes] All rights reserved.
Manuscript submitted June 9, 2015; revised manuscript received July 23, 2015. Published August 5, 2015.
Through silicon via (TSV) is one of the key technologies for the surface will be predominantly covered by accelerator after the depo-
three-dimensional (3D) IC/Si integration that can further enhance the sition time exceeding 1000 s if the displacement of the suppressor by
performances of integrated circuit (IC).1,2 It provides the shortest the accelerator is considered. This would cause the conformal filling
vertical interconnections with a large number of significant advan- model,18 which is not coincide with the real large dimension TSVs
tages, such as a wide bandwidth, smaller form factor, lower energy filling experiments. Tatsuro Matsuoka et al. and Liu Yang et al. use the
consumption, higher density, and improved electrical performance.1 diffusion-adsorption mechanism to explain the TSVs filling process,
Damascene process is widely used for fabricating on-chip intercon- respectively.2,19 However, the incorporation of organic additives into
nections in ultra large scale integrations (ULSIs).3,4 To accomplish the deposits is not considered in their models. It is worth noting that
void-free filling, several additives such as bis(3-sulfopropyl)disulfide the models mentioned above are reasonable in Damascene or special
(SPS), poly(ethylene glycol) (PEG), Janus green B (JGB), and chlo- structure. Due to the complex filling process, the different mecha-
ride ions (Cl ) are usually introduced in the plating bath.510 The nisms may become predominant depending on the via dimension and
bottom-up superfilling model has been proposed by Moffat et al. and plating conditions.
explained by the curvature enhanced accelerator coverage (CEAC).3 Actually, the TSVs filling process is complex, which contains the
The Damascene process can provide a reference for electrode- physicochemical dynamic process. During the via filling process, the
positing copper in TSVs. However, the Damascene process usually additives and cupric ions diffusion, adsorption, desorption, incorpo-
results in large voids in the TSVs and the bottom-up superfilling can- ration, and oxidation-reduction reaction occur simultaneously in the
not be achieved easily. Because the dimension of TSVs is ca. 100 via solution and via surface.16,20,21 The dissolved oxygen along the via
times larger than that of Damascene structure, a longer plating time depth direction also affects the activation of accelerator, which oxi-
is needed for TSVs and the depletion of cupric ion cannot be ignored dizes Cu+ to Cu2+ .2,17,22 Besides, the convective transport of the addi-
during TSVs filling.11 The long plating time leads to a large consump- tives and cupric ions in the TSVs also affects the filling process.2325
tion of additives and abundant accelerator adsorption on the whole New model is urgently needed to simulate the complex TSVs
plating surface.11,12 Therefore, the acceleration effect due to CEAC filling process. In this paper, the diffusion of the additives and ions
is not enough to achieve bottom-up deposition in the TSVs. So the (chloride ions and cupric ions), the adsorption, desorption and in-
modifications have been incorporated into the CEAC framework.13,14 corporation of the additives, oxidation-reduction reaction in the via
However, these models have not included the transport and adsorp- solution and surface, and the dissolved oxygen along the via depth
tion processes associated with the suppressor.15 Actually, it has been direction are considered in this model simultaneously. At present, the
reported that the bottom-up filling model is closely related to the level set method (LSM) is generally used to simulate the vias filling
suppressor concentration.16 process. Arbitrary-Lagrangian-Eulerian (ALE) method can capture
A model based on the diffusion and adsorption mechanism was the advantages of both Lagrangian and Eulerian while minimizes
proposed by Rohan Akolkar et al.15 The distribution of the additives is their disadvantages. It combines Lagrangian mesh and Eulerian mesh
translated into time and location dependent copper deposition rates to together in a single analysis to provide the ability to predict the in-
simulate the vias filling process, and the effect of the local area reduc- teraction between fluid and structure elements.26,27 In this paper, the
tion during the via filling on the additives distribution is incorporated Arbitrary Lagrange-Eulerian (ALE) method is used to track the vias
into the simulation.15 However, it is assumed that the concentrations surface shifting during the vias filling process, and the TSVs filling
of the accelerator and cupric ions within the via remain constant and mechanism is analyzed according to the simulation results. At last,
equal to their bulk values, which may be inappropriate for the large the real wafer-segment TSVs are electroplated to verify the rationality
dimension of TSVs (ca. 100 times larger than Damascene structure) of the numerical model.
since the depletion of cupric ion and additives inside TSVs should
be considered.17 Besides, the displacement of the suppressor by the
accelerator due to competitive adsorption was assumed to occur on via The Additives-Assisted Electrodeposition Model
surface during the via filling process, which is suitable for the Dam-
In this section, a physicochemical model is built to investigate the
ascene structure. However, the filling time of TSVs is several orders
vias filling mechanism and the distribution of the additives surface
of magnitude longer than that of Damascene structure, and the via
coverage. In order to explore the transport of the additives and cupric
ion in the via, the Nernst-Planck equation is introduced. Based on
the mass conservation, a non-linear partial differential equation is
z
E-mail: gfding@sjtu.edu.cn; pcheng2008@sjtu.edu.cn achieved for each additive/ion presented in the electrolyte, which can
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Journal of The Electrochemical Society, 162 (10) D540-D549 (2015) D541
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D542 Journal of The Electrochemical Society, 162 (10) D540-D549 (2015)
influencing factor, and the fraction of vacant sites available for adsorp- for the cupric ions diffusion and deposition rates, provided
2 I
tion. Eq. 12 is based on the assumption that the accelerator adsorbed
CCu 2+ 2 CCu 2+
irreversibly on the additive-free copper surface, and the displacement = DCu 2+ k 2+ CCu 2+ I + kCu
A
2+ C Cu 2+ A
of the suppressor by the accelerator is neglected.18 If the displace- t z 2 R Cu
ment of the suppressor by the accelerator effect is considered, the via
f r ee
surface is predominantly covered by accelerator after the deposition + kCu 2+ CCu 2+ (1 I A ) [18]
time exceeds 1000 s. In analogy to Eq. 12, the adsorption rate of the In Eq. 18, the time derivative on the left side represents the accu-
suppressor on the free sites of the copper surface is given by Eq. 13. mulation of the cupric ions within the volume element. The first term
zk on the right side of Eq. 18 represents the net supply of cupric ions to
= f (z, , ) = k O2 exp [11] the differential element through the diffusion, and the second term in
k L
the square bracket represents the net deposition.
In analogy to cupric ions, a similar approach is applied to the
A,ads = k A C A (1 I A ) [12] evolution of the chloride ions. The mass balance of the chloride ions
across the differential cylindrical volume element within the via is
given by Eq. 19. In Eq. 19, the term in the square bracket represents
I,ads = k I C I (1 I A ) [13] chloride ions net incorporation.
where is the external influencing parameter, z is the distance from CCl 2 CCl 2 I
= DCl CCl I,ads + Cu
Cl C Cl Cu 2+ ,dep
the via bottom to the top surface of the via, = length/width (AR, t z 2 R Cl
aspect ratio) is the aspect ratio of the via, L is the depth of the via, ko2 [19]
is the oxidation factor, k is the convection factor. I and A represent At the via opening, the concentration of the species is equal to its
the suppressor and the accelerator surface coverage, respectively, kI bulk concentration (C ).
and kA are the adsorption rate constant of the suppressor and the At z = L, C I = C I , C A = C
A , C Cu 2+ = C Cu 2+ , C Cl = C Cl
accelerator, respectively. [20]
The mass balance of the suppressor across a differential cylindrical At the via bottom (z = 0),
volume element within the via is shown in Fig. 1b. The analytical
expression for the diffusion, adsorption, and incorporation rates of the C I C A CCu 2+ CCl I A
= 0, = 0, = 0, = 0, = 0, =0
suppressor is given in 14. z z z z z z
C I 2C I 2 [21]
= DI [k I C I (1 I A ) + Cu
I C I Cu 2+ ,dep ] [14]
t z 2 R At the initial stage (t = 0), there do not exist any suppressor or
accelerator in the via, so the initial concentration of the suppressor
In Eq. 14, the time derivative on the left side represents the accumula-
and accelerator inside the via and their surface coverages can be set to
tion of the suppressor within the volume element. The first term on the
zero. The cupric ion and chloride ion concentration are equal to their
right side of Eq. 14 represents the net supply of the suppressor to the
bulk concentration, respectively.
differential by the diffusion, and the second term in the square bracket
indicates the net removal. The latter is determined by the balance be- C I (z) = 0, I (z) = 0, C A (z) = 0, A (z) = 0,
tween the suppressors adsorption on the via surface and removal rate [22]
from the electrolyte due to its incorporation into the copper. While the CCu 2+ = CCu 2+ , C Cl = C Cl
evolution of the accelerator surface coverage is described by
The electroneutrality constraint is given by the following
I 1 expression:
= [k I C I (1 I A )] [15]
t I
z i Ci = 0 [23]
where CuI is the suppressor incorporation constant, I is the sup- i
pressor surface concentration at the saturation, Cu 2+ ,dep is the flux of
cupric ions leaving electrolyte due to the electrodeposition. Desorption of the additives. In the electrolyte containing the
In analogy to the suppressor, a similar approach based on the suppressor and chloride ions, the suppressor would desorb from the
derivation for the suppressor is applied to the evolution of the ac- via surface when the local potential is lower than that of local critical
celerator. The mass balance of the accelerator across the differential desorption.31 The local critical desorption potential Udes is determined
cylindrical volume element within the via is given by by the local concentrations of the suppressor, Cu2+ , and Cl according
C A 2C A 2 to Eq. 24:
= DA [k A C A (1 I A ) + Cu
A C A Cu 2+ ,dep ]
t z 2 R
Udes = Ud0 + 0.0592 b log(Cl CCl )
[16]
where Cu is the accelerator incorporation constant. In Eq. 16, the 1
A log C I + d log(Cu 2+ CCu 2+ ) [24]
time derivative on the left side represents the accumulation of the c
accelerator within the volume element. The first term on the right side
of Eq. 16 indicates the net supply of the accelerator to the differential where the coefficients b, c, d, and potential Ud0 are 1, 10, 0.5, and
element through the diffusion, and the second term in the square 0.36 V (vs. saturated hydrogen electrode (SHE)), respectively.31 For
bracket represents its net removal. the plating bath used in this simulation, the constant activity coefficient
The increased rate of the accelerator surface coverage on the via i of 0.1 and 0.5 were assumed for Cu2+ and Cl , respectively.31
surface is equal to its net adsorption rate. Therefore, the changing rate When the local applied current density i is larger than the local
of the accelerator surface coverage is given by critical current density ic , the desorption of the adsorbed suppressor
occurs. The value of local ic is calculated using Eq. 25 with = Udes
A 1 U0 .
= [k A C A (1 I A )] [17]
t A CCu 2+ I F f r F
ic = i 0,I I exp +i 0, f r (1 I ) exp
The mass balance of the Cu2+ across a differential cylindrical CCu 2+ Rg T Rg T
volume element within the via, coupled with the analytical expression [25]
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Journal of The Electrochemical Society, 162 (10) D540-D549 (2015) D543
Equations 1119, 24, 25 with the boundary conditions of Eqs. 20, The overall current density is the sum of the suppressor-adsorbed
21, and the initial condition of Eq. 22 constitute a time-dependent copper deposition fractional current density iI , the accelerator-
(transport, adsorption, incorporation, and desorption) model for the adsorbed copper deposition current density iA , and the copper de-
additives, and the model provides a time-dependent additives distri- position at vacant sites ifree . Thus, the overall current density is given
bution inside the via. by
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D544 Journal of The Electrochemical Society, 162 (10) D540-D549 (2015)
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Journal of The Electrochemical Society, 162 (10) D540-D549 (2015) D545
and bottom region of the via. Figure 6c shows the suppressor surface
coverage along the via depth direction. The suppressor surface cov-
erage is much higher (ca. 0.85) in the via top region and decreases
steeply along the via depth direction, which is due to the low diffusion
coefficient and high adsorption rate constant of the suppressor. This
would inhibit the copper deposition in the opening region of the via.
Due to the high deposition rate in the via bottom region, the cupric
ion is consumed dramatically in this area and cannot be replenished
timely through the diffusion process, so the cupric ion concentration
decreases sharply along the via depth direction, as shown in Figure 6a.
Besides, the depletion of the cupric ion would reduce the current den-
sity in the via bottom region. As shown in Figure 6d, the distribution
of the cupric ion, suppressor, and accelerator result in the special cur-
rent density distribution inside the via. There is a steep increase, and
then a gradually decrease along the via depth direction, which would
cause a merger in the middle region of the via in advance and a large
void would be formed in the bottom region.
A further decrease in the accelerator concentration leads to a sig-
nificant change of the via filling profiles. Figure 7 shows the classical
V shaped filling profile of the via. The electroplating bath com-
ponent is Cacc = 0.5 ppm and Csup = 6 ppm. As shown in Figure 7,
when the accelerator concentration decreases to 0.5 ppm, the inhibited
region by the suppressor increases in the upper part of the via, and
the copper deposition rate increases linearly along the via depth direc-
tion. Due to the decrease of the accelerator concentration in the plating
bath, the suppressor dominates the additive surface coverage. As men-
tioned above, the diffusion coefficients (adsorption rate constant) of
the accelerator is much higher (lower) than that of the suppressor. The
accelerator diffuses into the via bottom in advance and dominates the
Figure 4. Simulated time-dependent variables in the 40 m140 m TSV
using the plating bath (Cacc = 4 ppm, Csup = 0 ppm). (a) Concentrations of surface coverage in the via bottom region (shown in Figure 8b). It
cupric ion; (b) Accelerator surface coverage; (c) Current density along the via can be seen from Figure 8c that the suppressor dominates the additive
depth direction. surface coverage in the via top region and decreases sharply along
the via depth direction. The high suppressor surface coverage in the
via top region inhibits the copper deposition effectively on the upper
sidewall, which is beneficial to the void-free filling. The current den-
suppressor only adsorbs in the via opening region speedily due to sity increases gradually along the via depth direction, which causes
the low diffusion coefficient and high adsorption rate constant of the the V shaped filling model.
suppressor, while the accelerator diffuses into the via fast and exists The extreme bottom-up filling model is achieved when using one-
in the middle and bottom region of the via due to the high diffu- component plating bath only with the suppressor additive (Cacc =
sion coefficient and low adsorption rate constant. It can be seen from 0 ppm, Csup = 6 ppm) only. As shown in Figure 9a, the sidewall of
Figure 6b that the accelerator surface coverage (ca. 0.1 0.2) is low the via is suppressed dramatically, and the bottom of the via has a
in the via opening region and increases sharply along the via depth high deposition rate. A clear division exists between the fast growing
direction, which would accelerate copper deposition in the middle bottom and the dramatically suppressed lateral wall. At the beginning
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D546 Journal of The Electrochemical Society, 162 (10) D540-D549 (2015)
Figure 6. Simulated time-dependent variables in the 40 m140 m TSV using the plating bath (Cacc = 3 ppm, Csup = 6 ppm). (a) Concentration of cupric
ion; (b) Accelerator surface coverage; (c) Suppressor surface coverage; (d) Current density along the via depth direction.
of the electroplating, the suppressor is depleted inside the via due to density to concentrate on the via bottom region. The sidewall of the
its fast adsorption rate and slow diffusion coefficient. As the suppres- via is almost covered by the suppressor as the diffusion process pro-
sor molecules diffuse from the bulk into the via, the boundary of the gressed, which inhibits the copper deposition on the via sidewall. As
saturated surface region moves gradually toward the via bottom, and illustrated in the additives-assisted electrodeposition model, all of the
the uncovered surface decreases gradually, which causes the current sidewalls and field are inhibited by the suppressor, and almost all of
the current density concentrates on the via bottom. When the local
applied current density is larger than the local critical current density,
the adsorbed suppressor desorbs in the via bottom region and the ex-
treme bottom-up filling model starts. The high copper deposition rate
in the via bottom is beneficial to sustaining the extreme bottom-up
filling model. Due to the significant inhibition effect on the sidewall,
there is little cupric ion to deposit into the via sidewall, which pro-
vides more cupric ion to diffuse into the via bottom and replenish the
cupric ion consumption, so there exists high cupric ion concentration
in the via bottom region (Figure 9c). Besides, the sustained bottom-up
filling process is actually beneficial to the void-free filling for high
aspect ratio TSVs as shown in both simulation and the following
real-world filling experiments. In Filling experimental of the blind
via using different plating chemistry section, the real-world via filling
experiments are conducted to verify the rationality of the proposed
model.
Specifically, the convenient parameter is proposed =
i i top 41
100[ bottom
i top
]. When > 0, the supperfilling model would be
achieved. When < 0, the void filling model would appears. Only
when 0, the nearly conformal filling model is difficult to predict
whether the void-free filling appears or not. According to the simulated
results, when there are large doses of accelerators in the plating bath,
the void filling model would occur ( < 0). When there are small
doses of accelerators and large doses of suppressors in the plating
Figure 7. Simulated evolution of the filling profile and distribution of the bath, the void-free filling (V shaped or extreme bottom-up filling
current density for the 40 m140 m TSV using the plating bath (Cacc = model) model would occur. The simulation results could provide a
0.5 ppm, Csup = 6 ppm). qualitative guidance for the real-world via filling experiment.
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Journal of The Electrochemical Society, 162 (10) D540-D549 (2015) D547
Figure 8. Simulated time-dependent variables in the 40 m140 m TSV using the plating bath (Cacc = 0.5 ppm, Csup = 6 ppm). (a) Concentration of cupric
ion; (b) Accelerator surface coverage; (c) Suppressor surface coverage; (d) Current density along the via depth direction.
Filling experimental of the blind via using different plating bottom which is almost perpendicular to the slow-growing lateral
chemistry. The filling experiments of the blind vias using differ- wall. A clear division appears between the fast deposition bottom and
ent plating chemistry are performed to verify the rationality of the the significantly inhibited lateral wall. The large suppressor surface
proposed model. Figure 10a shows the cross-sectional image of the coverage in the field and sidewall of the via extremely inhibits the
via filling result using one-component plating bath only with the ac- copper deposition in those regions. Large current density in the via
celerator (Cacc = 4 ppm, Csup = 0 ppm). It can be seen that the via bottom makes the desorption of the suppressor possible. Besides, the
opening merges in advance and results in a large void in the via, which sustained bottom-up filling process is actually beneficial to the void-
is in accordance with the simulation result (Figure 3). As illustrated free filling for high-aspect-ratio TSVs as shown in both simulation
in the simulation part, the depletion of cupric ions in the via bottom and real-world filling experiment.
are the main reason to cause the void forming. The via filling process is dominated by the diffusion-adsorption-
A two-component electroplating bath (Cacc = 3 ppm, Csup = 6 ppm) desorption competition mechanism between the suppressor and the
is used in the via filling experiment. As shown in Figure 10b, there accelerator. Although a tiny discrepancy exists between the simulated
exists a protuberance in the middle region of the via. As illustrated filling profiles and the real-world via filling ones, they almost show
in the simulation part, the distributions of the cupric ion, suppressor, the same filling tendency. So, the model and mechanism proposed in
and accelerator result in the special distribution of the current density this study provides a guidance for the real-world via filling.
inside the via. The current density increases steeply at first, and then
a gradually decreases along the via depth direction, which causes a Conclusions
protuberance in the middle region of the via and a large void forms in
the bottom region. A physicochemical model is built to investigate the via filling
With a decrease of the accelerator concentration (Cacc = 0.5 ppm, mechanism. Finite element method (FEM) and multifrontal massively
Csup = 6 ppm), the protuberance disappears (Figure 10c). Due to parallel sparse direct solver (MUMPS) are employed to solve the nu-
the large dose of suppressor, the suppressor dominates the additive merical model considering the transport, adsorption, incorporation,
surface coverage and decreases slightly along the via depth direction. and desorption of the additives and ions. The motion of the fluid-
The copper deposition rate increases linearly along the via depth structure interface (metal/electrolyte interface) is tracked using the
direction. Fewer cupric ions are consumed in the upper part of the Arbitrary Lagrange-Eulerian (ALE) method during the via filling pro-
via, which provides more cupric ions to diffuse into the via bottom to cess. The Nernst-Planck equation is introduced to explore the transi-
replenish the consumption of the cupric ions. So the V shaped via tion of the additives and cupric ions. Compared to the reported mod-
filling model appears. els, the diffusion of the additives (accelerator and suppressor) and ions
When the accelerator concentration decreases to 0 ppm, the ex- (cupric ion and chloride ion), the adsorption/desorption/incorporation
treme bottom-up filling model occurs, which is in accordance with of the accelerator, suppressor, cupric ion and chloride ion, the accel-
the simulation profile (Figure 9a). As shown in Figure 10d, the ex- erator deactivation, and copper deposition processes are all included
treme bottom-up filling model is characterized by a fast-growing flat in this model.
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D548 Journal of The Electrochemical Society, 162 (10) D540-D549 (2015)
Acknowledgments
This work is sponsored by National Basic Research Priorities Pro-
gram of China (No. 6132042012) and Chinese National Science and
Technology Major Project (No. 2011ZX02702-003).
List of Symbols
C concentration, mol cm3
D diffusion coefficient, cm2 s1
J flux of species in solution mol/cm2 s
F Faradays constant, 96487 C/equiv
Rg universal gas constant, 8.314 J/mol K
R radius of through silicon via, m
i current density, A cm2
T absolute temperature, K
M molecular weight of the copper, 63.55 g/mol
n number of electrons transferred in copper deposition, 2
t time, s
z position coordinate, m
k adsorption rate constant for the additive, cm/s
Greek
electric potential inside the electrolyte solution, V
activation overpotential at the electrode surface, V
cathodic transfer coefficient, mol1
surface concentration at saturation, mol/cm2
surface coverage, dimensionless
density of copper, 8.92 g/cm3
external influence parameter, dimensionless
Figure 9. (a) Simulated evolution of the TSVs filling profile using the plating aspect ratio, dimensionless
bath (Cacc = 0 ppm, Csup = 6 ppm); (b) Simulated time-dependent suppressor
surface coverage; (c) Simulated time-dependent cupric ion concentration. Subscripts
A related to the accelerator
I related to the suppressor
The simulation results are achieved according to the proposed Cu related to copper
model. shape filling model appeared when only the accelerator Cl related to chloride ion
is used in the plating bath. The protuberance appears in the middle diff related to diffusion
of the via when large dose of accelerator (Cacc = 3 ppm, Csup = ads related to adsorption
6 ppm) is used in the plating bath, which will cause the void filling related to rotation speed
model. The V shape filling model is achieved when large dose of
suppressor and small dose of accelerator (Cacc = 0.5 ppm, Csup = Superscripts
6 ppm) are used in the bath. An extreme bottom-up filling model is
achieved when the plating bath only contained suppressor (Csup = related to bulk value
6 ppm). The via filling process is dominated by the diffusion- free occuring on an unoccupied site
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Journal of The Electrochemical Society, 162 (10) D540-D549 (2015) D549
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