Integrated circuit bonding pads including conductive layers with arrays of unaligned spaced apart insulating islands therein and methods of forming same

[0002] This application is a Continuation-In-Part (CIP) of application Ser. No. 09/663,996 filed Sep. 18, 2000 now U.S. Pat. No. 6,465,337, which is a divisional of application Ser. No. 09/387,954 filed Sep. 1, 1999 now U.S. Pat. No. 6,163,074, which is a CIP of application Ser. No. 09/103,970 filed Jun. 24, 1998 now U.S. Pat. No. 6,228,270, all of which are assigned to the assignee of the present application. This application hereby claims the benefits of these cross-referenced applications, the disclosures of which are hereby incorporated herein by reference in their entireties.

[0003] This invention relates to integrated circuits and methods of forming the same, and more particularly to bonding pads for integrated circuits and methods of forming the same.

[0004] Integrated circuits, also referred to as “chips”, are widely used in consumer and commercial electronic products. As is well known to those having skill in the art, an integrated circuit generally includes a substrate such as a semiconductor substrate and an array of bonding pads on the substrate. The bonding pads provide an electrical connection from outside the integrated circuit to microelectronic circuits in the integrated circuit.

[0005] FIG. 1 is a schematic view of an integrated circuit package including a plurality of bonding pads. As shown in FIG. 1, an integrated circuit 100, for example, a memory integrated circuit that includes a memory cell array portion 110 and a peripheral circuit portion 115, may include a plurality of bonding pads 200. The bonding pads 200 can act as a gate for a circuit terminal of the integrated circuit 100 and may be internally connected to an input/output (IO) buffer circuit in the peripheral circuit portion 115.

[0006] As shown in FIG. 1, the integrated circuit 100 is attached to a lead frame 300. Wire bonding or other conventional techniques may be used to connect a respective wire 320 to a bonding pad 200 and to an inner lead tip 310 of the lead frame 300.

[0007] FIG. 2 is an enlarged top view of a bonding pad 200 of FIG. 1. FIG. 3 is a perspective view of the bonding pad of FIG. 2. FIG. 4 is a sectional view of the bonding pad taken along line IV-IV′ of FIG. 2, and FIG. 5 is a sectional view of the bonding pad taken along line V-V′ of FIG. 2.

[0008] In a conventional bonding pad structure as shown in FIGS. 2 through 5, independent conductive plugs 245, such as tungsten plugs fill a plurality of via holes 240 in an interconnection dielectric layer 250. The conductive plugs 245 electrically connect a lower aluminum interconnection layer 230 with an upper aluminum interconnection layer 260. Reference numerals 210, 220, and 270 denote an integrated circuit substrate, an interdielectric layer, and a wire bonding region, respectively.

[0009] Unfortunately, the pad structure shown in FIGS. 2 through 5 may have problems. For example, as shown in FIGS. 4 and 5, during sorting for separating good integrated circuits 100 from a wafer, cracks 330 may occur in the interconnection dielectric layer 250 due to the force of a probe pin of a tester that is applied to the wire bonding region 270. The cracks 330 also may occur in the interconnection dielectric layer 250 due to stress caused by mechanical impact and pressure applied during bonding of a wire 320 in the wire bonding region 270.

[0010] Cracks may occur because the upper aluminum interconnection layer 260 and the lower aluminum interconnection layer 230 which are relatively soft, may change in shape due to the stress applied during the sorting or wire bonding. However, the interconnection dielectric layer 250 which is relatively hard, does not readily change in shape. Thus, a stress higher than a predetermined value can cause a slip of unstable tungsten plugs 245 or cracks in the interconnection dielectric layer 250. The cracks 330 may extend to the inside of the insulating layer 250 surrounding the tungsten plugs 245 as shown in FIG. 5.

[0011] The cracks occurring in the interconnection dielectric layer 250 may generate an interconnection layer-open problem in which the upper and the lower interconnection layers 260 and 230 slip. Alternatively, a pad-open problem may be created in which contact between the wire 320 and the upper aluminum interconnection layer 260 becomes bad such that the wire 320 slips from the upper aluminum interconnection layer 260.

[0012] FIG. 6 is a top view of another conventional bonding pad structure in which tungsten plugs 245 are formed only in a peripheral region around the outside of the central wire bonding region, to reduce the interconnection dielectric layer cracking and to reduce interconnection layer or wire slipping. FIG. 7 is a sectional view of the bonding pad structure taken along line VII-VII′ of FIG. 6. This bonding pad structure is disclosed in U.S. Pat. No. 5,248,903 and U.S. Pat. No. 5,502,337.

[0013] A bonding pad structure according to FIGS. 6 and 7 and the above two patents, may reduce the cracks of the interconnection dielectric layer 250. However, the number of the tungsten plugs 245 also is reduced, which can result in a weaker attachment between the tungsten plug 245 and the upper aluminum interconnection layer 260. As a result, the interconnection layer-open phenomenon, in which the upper aluminum interconnection layer 260 is broken, may more easily occur during wire bonding. Also, since the number of plugs is reduced, which may reduce the area for contacting the upper aluminum interconnection layer 260, an increase in the resistance R_Sand a reduction of current may result. Thus, sufficient current may not be supplied to a switching device in the integrated circuit, which may deteriorate the operation of the device.

[0014] Embodiments according to the present invention can provide bonding pads and methods that include arrays of unaligned spaced apart insulating islands. Pursuant to these embodiments, bonding pads for integrated circuits can include first and second spaced apart conductive layers, a third continuous conductive layer between the first and second spaced apart and an array of unaligned spaced apart insulating islands in the third continuous conductive layer that extends therethrough such that sidewalls of the array of insulating islands are surrounded by the third continuous conductive layer.

[0015] In some embodiments, the array can include rows of unaligned spaced apart insulating islands and columns of unaligned spaced apart insulating islands. In other embodiments, the array of unaligned spaced apart insulating islands can also include a first insulating island having a first edge in a first direction and a second insulating island, adjacent to the first insulating island in the first direction having a second edge in the first direction that is unaligned with first edge.

[0016] In some embodiments, the bonding pad can further include a fourth continuous conductive layer between the third continuous conductive layer and the second conductive layer that is electrically connected to the third continuous conductive layer and to the second conductive layer. A second array of spaced apart insulating islands in the fourth continuous conductive layer extends therethrough such that sidewalls of the second array of insulating islands are surrounded by the fourth continuous conductive layer, wherein the second array of spaced apart insulating islands in unaligned with the first array of unaligned spaced apart insulating islands.

[0017] In some embodiments, the bonding pad can further include a metal bumper layer on a conductive layer and an upper bonding pad layer on the metal bumper layer that is configured to bond with a wire. In some embodiments, the metal bumper layer is tungsten. In still other embodiments, the metal bumper layer has a thickness of about 4000 Å. In other embodiments, the metal bumper layer and the upper bonding pad layer can be a single layer having a thickness in a range between about 12000 Å to 14000 Å. In some embodiments, the upper bonding pad layer is directly on the metal bumper layer.

[0018] In some embodiments, the metal bumper layer includes insulating islands that are located towards the outer edges of the metal bumper layer. In other embodiments, an inner region of the metal bumper layer is free of insulating islands.

[0019] In other embodiments, bonding pad structures according to the present invention can include first and second spaced apart conductive layers and a third continuous conductive layer between the first and second spaced apart conductive layers that is electrically connected to the first and second spaced apart conductive layers. The bonding pad structure further includes an array of spaced apart insulating islands in the third continuous conductive layer in a zig-zag arrangement that extends therethrough such that sidewalls of the array of insulating islands are surrounded by the third continuous conductive layer.

[0020] Embodiments of methods according to the present invention can include forming an underlying conductive layer on an integrated circuit substrate. A continuous conductive layer is formed on the underlying conductive layer and electrically connected thereto. The continuous conductive layer includes therein an array of unaligned spaced apart insulating islands that extend therethrough such that sidewalls of the insulating islands are surrounded by the continuous conductive layer. An overlying conductive layer is formed on the continuous conductive layer and electrically connected thereto.

[0021] In other embodiments, the act of forming a continuous conductive layer can include forming a continuous conductive layer including rows of unaligned spaced apart insulating islands. In other embodiments, the act of forming a continuous conductive layer can include forming a continuous conductive layer including rows of unaligned spaced apart insulating islands and columns of unaligned spaced apart insulating islands.

[0022] In some embodiments, the act of forming a continuous conductive layer can include forming a first insulating island having a first edge in a first direction in the continuous conductive layer and forming a second insulating island, adjacent to the first insulating island in the first direction, having a second edge in the first direction that is unaligned with first edge in the continuous conductive layer.

[0023] FIG. 1 is a schematic view of an integrated circuit attached to a lead frame.

[0024] FIG. 2 is an enlarged top view of a conventional bonding pad structure of FIG. 1.

[0025] FIG. 3 is a perspective view of the bonding pad structure of FIG. 2.

[0026] FIG. 4 is a sectional view of the bonding pad structure taken along line IV-IV′ of FIG. 2.

[0027] FIG. 5 is a sectional view of the bonding pad structure taken along line V-V′ of FIG. 2.

[0028] FIG. 6 is a top view of another conventional bonding pad structure.

[0029] FIG. 7 is a sectional view of the bonding pad structure taken along line VII-VII′ of FIG. 6.

[0030] FIG. 8 is a top view of a bonding pad structure according to a first embodiment of the present invention.

[0031] FIG. 9 is a perspective view of the bonding pad structure of FIG. 8.

[0032] FIG. 10 is a sectional view of the bonding pad structure taken along line X-X′ of FIG. 8.

[0033] FIG. 11 is a sectional view of the bonding pad structure taken along line XI-XI′ of FIG. 8.

[0034] FIG. 12 is a top view of a bonding pad structure according to a second embodiment of the present invention.

[0035] FIG. 13 is a perspective view of the bonding pad structure of FIG. 12.

[0036] FIG. 14 is a sectional view of the bonding pad structure taken along line XIV-XIV′ of FIG. 12.

[0037] FIG. 15 is a sectional view of the bonding pad structure taken along line XV-XV′ of FIG. 12.

[0038] FIG. 16 is a top view of a bonding pad structure according to a third embodiment of the present invention.

[0039] FIG. 17 is a top view of a bonding pad structure according to a fourth embodiment of the present invention.

[0040] FIG. 18 is a top view of a bonding pad structure according to a fifth embodiment of the present invention.

[0041] FIG. 19 is a top view of a bonding pad structure according to a sixth embodiment of the present invention.

[0042] FIG. 20 is a block diagram of methods of fabricating bonding pad structures according to the present invention.

[0043] FIG. 21 is a graph showing the pulling strength of a wire bonded to a bonding pad structure according to the present invention compared to a conventional bonding pad.

[0044] FIG. 22 is a graph showing pad-open and interconnection layer-open in a bonding pad structure according to the present invention compared to a conventional bonding pad structure.

[0045] FIGS. 23 through 26 are top views that illustrate embodiments of bonding pad structures that include arrays of unaligned spaced apart insulating islands according to the present invention.

[0046] FIGS. 27 though 30 are cross-sectional views that illustrate embodiments of bonding pad structures that include metal bumper layers according to the present invention.

[0047] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the thickness of layers and regions are exaggerated for clarity. It will be understood that when an element such as a layer, region or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. Like numbers refer to like elements throughout.

[0048] In FIG. 8, reference numerals 920, 925I, 930, and 940 denote a lower interconnection layer, a lower island insulator, a lower single-bodied conductive plug, and an intermediate interconnection layer, respectively. Reference numerals 945I, 950, 960, and 970 denote an upper island insulator, an upper single-bodied conductive plug, an uppermost interconnection layer, and a wire bonding region, respectively. Reference numerals 925 and 945 denote an interdielectric layer surrounding an outer wall of lower and upper single bodied conductive plug patterns, respectively. Single-bodied conductive plugs also may be referred to as continuous conductive layers. The interconnection layers also may be referred to as conductive layers and the island insulators also may be referred to as insulating islands. It also will be understood that the terms “upper”/“lower” and “top”/“bottom” are used to indicate respective relationships remote from/adjacent an integrated circuit substrate, rather than absolute directions.

[0049] Referring to FIGS. 9, 10 and 11, an interdielectric layer 910 is on an integrated circuit substrate 900, and a bonding pad structure having a triple-layered interconnection including the lower interconnection layer 920, the intermediate interconnection layer 940 and the uppermost interconnection layer 960 is on the interdielectric layer 910. The uppermost interconnection layer 960 includes the wire bonding region 970 to which a wire 990 is bonded. The wire 990 can act the gate for a circuit terminal connected to a peripheral I/O buffer circuit 115 (see FIG. 1).

[0050] The upper single bodied conductive plug 950 is arranged between the bottom surface of the uppermost interconnection layer 960 and the top surface of the intermediate interconnection layer 940 to thereby electrically connect the uppermost interconnection layer 960 and the intermediate interconnection layer 940. At least one upper island insulator 945I having sidewalls surrounded by the single bodied conductive plug, and upper and lower surfaces surrounded by the uppermost interconnection layer 960 and the intermediate interconnection layer 940, is formed in the upper single bodied conductive plug 950. As shown, an array of upper island insulators 945I preferably are provided.

[0051] The number and/or size of the upper island insulators 945I preferably are chosen such that they are within a range in which the area of the upper single conductive plug 950 contacting the uppermost interconnection layer 960 is 10% or more of the area of the uppermost interconnection layer 960. The contact area is 10% or more so that current of a predetermined value or higher can flow to the bonding pad portion. Preferably, a plurality of island insulators 945I, also referred to as an array of spaced apart insulating islands, can reduce the width of the island insulator 945I. Stated differently, an insulating layer interposed between the uppermost interconnection layer 960 and the intermediate interconnection layer 940 is partitioned into a plurality of island insulators 945I in the upper single bodied conductive plug 950. Accordingly, even if one of the island insulators 945I is cracked, other island insulators 945I may not be cracked. In general, the uppermost interconnection layer 960 functioning as a bonding pad is square in shape and has a size of 100 μm×100 μm. Preferably, the interval between the upper island insulators 945I is between about 0.3 μm and about 10 μm. Particularly, a plurality of island insulators 945I are arranged in a matrix so that the upper single bodied conductive plug 950 is formed as a mesh and thus the island insulators 945I may not crack under stress up to predetermined value.

[0052] The structure for connecting the intermediate interconnection layer 940 and the lower interconnection layer 920 preferably is the same as that which connects the intermediate interconnection 940 and the uppermost interconnection 960. That is, the intermediate interconnection 940 and the lower interconnection 920 are electrically connected by the lower single bodied conductive plug 930 including at least one lower island insulator 925I.

[0053] The above-described bonding pad structure is a triple-layered interconnection layer according to the first embodiment of the present invention. However, the bonding pad structure can be a double-layered interconnection layer, including the uppermost interconnection layer 960 and the intermediate interconnection layer 940, or a multi-layered interconnection layer.

[0054] The effect of a bonding pad structure according to the first embodiment of the present invention will be described with reference to the structure for connecting the uppermost interconnection layer 960 and the intermediate interconnection layer 940. A bonding pad structure according to the present invention may be regarded as a reversal of a conventional bonding pad structure in which the uppermost interconnection layer 260 (of FIG. 3) and the lowermost interconnection layer 230 (of FIG. 3) are insulated by a single bodied insulating layer 250 (of FIG. 3), and a plurality of independent conductive plugs 245 (of FIG. 3) in the insulating layer 250 connect the uppermost interconnection layer 260 and the lowermost interconnection layer 230. Rather, according to the invention, the conductive plug 950 connecting the uppermost interconnection 960 and the intermediate interconnection 940 becomes a continuous conductive plug, and at least part of the insulating layer interposed between the uppermost interconnection layer 960 and the intermediate interconnection layer 940 is partitioned into at least one island insulator 945I in the single bodied conductive plug 950.

[0055] The island insulator 945I has a sidewall completely surrounded by the single bodied conductive plug 950 and top and bottom surfaces covered with the interconnection layers 960 and 940, so that it has a stable structure. Thus, when a mechanical stress of a known amount is applied during chip sorting and/or wire bonding, the island insulator 945I may not crack. Also, in the case where a crack does form in an island insulator 945I, the crack may not extend to an adjacent island insulator 945I.

[0056] Referring now to FIG. 12 through FIG. 15, in a second embodiment, an intermediate interconnection layer 940′ is not formed in a continuous plate shape, but rather includes an island insulator 935I like the upper and the lower single bodied conductive plugs 950 and 930. Thus, the island insulators in the intermediate interconnection layer can overlap the island insulators in the upper and the lower single bodied conductive plugs 950 and 930. Preferably, the island insulator 945I in the upper single bodied conductive plug 950 and the island insulator 925I in the lower single bodied conductive plug 930 are connected to the island insulator 935I in the intermediate interconnection 940′, to thereby form one island insulator I. When the island insulators 945I and 925I in the upper and the lower conductive plugs 950 and 930 and the island insulator 935I interposed in the intermediate interconnection are connected to be one island insulator, the thickness of the island insulator I is the sum of the thicknesses of the three insulators 925I, 935I and 945I, such that the resistance to stress may be increased.

[0057] Referring to FIG. 16, in a third embodiment, a plurality of island insulators 925I and 945I are formed in a zig-zag arrangement.

[0058] Referring to FIG. 17, in a fourth embodiment, island insulators 945I′ and 925I′ are of a cylinder shape. Also, the island insulators may be formed by various multiangular or polygonal prisms, such as triangular or pentaangular prisms.

[0059] Referring to FIG. 18, in a fifth embodiment, single bodied conductive plugs 930′ and 950′ are formed only under peripheral regions around the outside of the region covered by wire bonding region 970 of the uppermost interconnection layer, and insulators 929 and 949 are formed under the central wire bonding region 970. According to the fifth embodiment, plugs which can potentially seed a crack are not formed under the wire bonding region 970, so that cracks may not occur in the insulators 929 and 949, and a predetermined contacting area with the uppermost interconnection layer 960 can be provided by the single bodied conductive plugs 930′ and 950′ formed under the regions around the periphery of the wire bonding region.

[0060] Referring to FIG. 19, in a sixth embodiment, the island insulators 925I′ and 955I′ that are formed in the single bodied conductive plugs 930′ and 950′ are elongated.

[0061] Methods of forming a bonding pad structure of FIG. 9 according to the first embodiment of the present invention now will be described, with reference to FIG. 20.

[0062] The step of forming an intermediate interconnection 940 and an uppermost interconnection 960 will be described. At Block 2000, the intermediate interconnection 940 is formed on an integrated circuit substrate 900 where underlayers 910, 920 and 930 have been formed. Subsequently, an interdielectric layer 945 is formed on the intermediate interconnection 940, at Block 2010. The interdielectric layer 945 may be formed by depositing an insulation material on the intermediate interconnection 940, and planarizing the resultant structure through etchback and/or chemical mechanical polishing.

[0063] Then, the interdielectric layer 945 is patterned using a mask to define a region where an upper single bodied conductive plug is to be formed, at Block 2020. Thus, the intermediate interconnection 940 is partially exposed, and a continuous trench defining at least one island insulator 945I is formed.

[0064] A plurality of island insulators 945I preferably are patterned in matrix or a zig-zag arrangement. An interval between the island insulators 945I, i.e., the width of the trench may be between about 0.3 μm and about 10 μm. A reason for forming an interval of 0.3 μm or more is to reduce cracking of an island insulator adjacent a cracked island insulator. Also, a reason for forming an interval of 10 μm or less is to sufficiently fill the trench between the island insulators with the conductive plug.

[0065] A conductive layer filling the trench is formed of a conductive material, e.g., tungsten, copper or aluminum, at Block 2030. Subsequently, the conductive layer filling the trench is planarized through etchback and/or chemical mechanical polishing to complete an upper single conductive plug 950 surrounding the sidewalls of the island insulators 945I, at Block 2040. Preferably, the total area of the top surface of the upper conductive plug 950 is 10% or more of the area of the uppermost interconnection 960 to be formed.

[0066] In another alternative, a solid conductive layer is formed on an underlying conductive layer, electrically connected thereto. A plurality of spaced apart vias is etched in the solid conductive layer that extend therethrough. An insulating layer is formed on the solid conductive layer and in the vias. The insulating layer is removed from on the solid conductive layer, for example using etchback and/or chemical mechanical polishing, such that the insulating layer remains in the vias.

[0067] Continuing with the description of FIG. 20, the uppermost interconnection 960 functioning as a bonding pad is formed on the top surface of the upper single bodied conductive plug 950 at Block 2050. Then, a planarization layer 980 is formed on the surface of the uppermost interconnection 960 at Block 2060. The planarization layer 980 preferably is formed of a material which is water resistant, resistant to stress, has a high step coverage and is uniform. Subsequently, the planarization layer 980 is patterned to expose the wire bonding region 970 of the uppermost interconnection 960 at Block 2070.

[0068] The process of forming layers under the intermediate interconnection layer 940, i.e., a lower interconnection layer 920 and a lower single bodied conductive plug 930 may be performed by the same steps as Blocks 2000 through 2040 before the step of forming the intermediate interconnection layer 940. The bonding pad structure of a multi-layered interconnection structure can be formed by repeating the steps for forming the underlayer structure.

[0069] In a method of fabricating a bonding pad structure (see FIGS. 13 and 14) according to the second embodiment, the intermediate interconnection layer 940′ may be formed in the same manner as the upper and lower single bodied conductive plugs 950 and 930. That is, a lower single bodied conductive plug 930 including a lower island insulator 925I is formed in Blocks 2000 through 2040, and then a single bodied intermediate interconnection 940′ including an intermediate island insulator 935I partially overlapping the lower single bodied conductive plug 930 is formed in Blocks 2010 through 2040. The step of forming the upper single bodied conductive plug 950 and the uppermost interconnection 960 may be performed in the same manner as the first embodiment. Preferably, the lower, intermediate and upper island insulators 925I, 935I and 945I are formed in one body.

[0070] The present invention now will be described with reference to the following Examples. These Examples shall not be construed as limiting the scope of the present invention.

[0071] First samples having a bonding pad structure according to the present invention were provided. That is, a four-layered aluminum interconnection was formed on a substrate and single-bodied, meshed tungsten plugs having island insulators separated by an interval of 3.4 μm were formed between interconnections, to thereby electrically connect the interconnections. A planarized layer was formed on the uppermost interconnection layer, and the resultant structure was patterned to expose a bonding wire region. Then, a wire was bonded by a wedge method to provide a sample.

[0072] After completing the bonding pad structure, the wire-pulling strength was measured using a wire-pulling strength measuring apparatus.

[0073] The number of first samples having a bonding pad structure according to the present invention was 170. Also, 197 first control samples having a conventional bonding pad as shown in FIG. 3 and170 second control samples having a conventional bonding pad as shown in FIG. 7 were provided. The wire-pulling strength of the control samples was measured in the same manner.

[0074] The measured results are shown in Table 1 and in FIG. 21. In FIG. 21, -∘- indicates the wire-pulling strength of a bonding pad (Sample 1) according to the present invention, -Δ- indicates the wire-pulling strength of a conventional bonding pad (Control Sample 1), and -□- indicates the wire-pulling strength of another conventional bonding pad (Control Sample 2), respectively. The accumulated distribution (%) indicates the percentage of the number of samples in which the wire slipped during an increase in the pulling strength from 0 g to 10 g. In Table 1, the accumulated distribution indicates the percentage of the number of samples in which the wire was separated at a value of 6 g or less of pulling strength.

[0075] It will be understood from Table 1 and FIG. 21 that the wire-pulling strength of a pad according to the present invention can be much higher than that of a conventional pad.

[0076] In testing the first sample and the first and second control samples which are the same as those of the first example, a pad-open phenomenon in which a wire slips due to bad contact between the wire and the aluminum interconnection layer acting as a bonding pad, and an interconnection-open phenomenon in which the interconnection layer slips during bonding, were measured. The pad-open and the interconnection-open were measured, and then the number of cracks generated from an island insulator under the uppermost aluminum interconnection layer or an interdielectric layer were measured in 158 of the first samples (Sample 1), 140 first control samples (Control Sample 1) and 142 of the second control samples (Control Sample 2). The planarized layer of each of the samples and the uppermost aluminum interconnection layer thereof were removed using an appropriate etching solution, and then the number of cracks were measured using a scanning electron microscope. The result is shown in Table 2 and in FIG. 22.

[0077] Referring to Table 2 and FIG. 22, many cracks were generated in the first control sample and the second control sample having a conventional pad structure, while no cracks were generated in the first sample having a pad structure according to the present invention. Also, the interconnection-open phenomenon did not occur since there were no cracks, and the number of occurrences of the pad-open phenomenon was remarkably reduced compared to conventional pad structures.

[0078] According to bonding pad structures of the present invention, an uppermost interconnection layer and an interconnection under the uppermost interconnection layer are connected by a continuous conductive plug, so that a contact area greater than or equal to a predetermined size may be obtained. Thus, sufficient current can be transmitted into the bonding pad structure.

[0079] Also, an insulating layer between the uppermost interconnection layer and the lower interconnection layer is formed as an island insulator in a single bodied conductive plug. Thus, cracks in the insulator caused by physical stress when a probe pin is applied for chip-sorting and/or when bonding a wire is applied may be reduced. Moreover, since the insulator is of an island type, cracks may be prevented from extending to a peripheral insulator.

[0080] Referring again to FIGS. 8 through 11, in some embodiments according to the present invention a plurality of insulating islands 945I can be arranged in an array so that the upper single bodied conductive plugs 950 are in a mesh pattern. The mesh arrangement of the upper single-bodied conductive plugs 950 may decrease the probability of a slip of an unstable upper single bodied conductive plug 950, even if there were stress between the upper single bodied conductive plug 950 and the insulating islands 945I. Accordingly, insulating islands 945I under a stress which is higher than a predetermined value, may not be cracked. Alternatively, if cracks occur, the cracks may not extend to other insulating islands 945I.

[0081] As shown in FIG. 8, a spacing D1 between the insulating islands 945I can be determined by considering whether or not cracks may extend to other insulating islands 945I and the conditions of the fabrication process. That is, the spacing D1 between the insulating islands 945I may be sufficiently large that the cracks occurring in one insulating island 945I may not extend to another insulating island 945I. In addition, in embodiments according to the present invention where the upper single bodied conductive plug 950 is formed by first forming the insulating islands 945I and then forming, therebetween and thereon, a conductive material, such as tungsten, and then planarizing the conductive material, the maximum spacing between the insulating islands 945I is preferably less than twice the thickness of the conductive material which is formed during the fabrication process so that the insulating island 945I may be more completely surrounded with the conductive material.

[0082] Preferably, the spacing D1 between the upper insulating islands 945I is between about 0.3 μm and about 10 μm. In embodiments according to the present invention where the conductive material used to form the upper single bodied conductive plug 950 has a thickness between about 0.4 μm and about 1 μm, the spacing between the upper insulating islands 945I is more preferably between about 0.3 μm and about 2 μm. In general, the upper interconnection layer 960 may function as a bonding pad and can be square and measure about 100 μm×100 μm.

[0083] FIGS. 23 through 26 are top views that illustrate arrays of unaligned or spaced apart insulating islands according to the present invention. As shown in FIGS. 23 and 24, in some embodiments according to the present invention, the insulating islands in the rows of the array are unaligned or offset from one another. Accordingly, only two angular-point portions of the insulating islands are adjacent to one another. Reducing the number of angular-point portions or comers of the insulating islands that are adjacent to one another may reduce the amount of light that is diffracted during photolithography.

[0084] In will be understood that in some embodiments according to the present invention, the insulating islands in the columns of the array can be unaligned or offset from one another. In still other embodiments, the insulating islands in the rows and the insulating islands in the columns of the array are also unaligned. In other embodiments according to the present invention, adjacent rows are offset from one another by, for example, half spacing. Alternate rows and/or columns can be aligned and adjacent rows and/or columns can also be unaligned or offset by half spacing therebetween. Other spacings can be used.

[0085] In further embodiments according to the present invention, the edges of the insulating islands may be unaligned as shown, for example, in FIG. 25. As shown in FIG. 25, edges 2501-2506 in the row direction of an unaligned array arrangement are unaligned with respect to one another. The unaligned edges 2501-2506 may further reduce the amount of diffraction during the photolithography process. In will be understood that the edges in the column direction of the unaligned array arrangement can be unaligned as well.

[0086] As shown in FIG. 26, edges 2601-2605 in the row direction and in the column direction can both be unaligned with respect to one another according to the present invention. In particular, edges 2601-2605 in the row direction of an unaligned array arrangement are unaligned with respect to one another and edges 2606-2609 in the column direction of the unaligned array arrangement are unaligned with respect to one another. The unaligned edges in both the row and column directions may further reduce the amount of diffraction during the photolithography process.

[0087] In contrast to embodiments according to the present invention FIGS. 25 and 26, the rows and columns of the array of insulating islands, illustrated for example in FIG. 8, are aligned. In such aligned arrangements, four angular points of the insulating islands may be adjacent to each other. Accordingly, diffraction occurring in each angular point of the insulating islands in the photolithography process can overlap, causing the parts of the pattern that correspond to the angular points to be rounded and thereby change the critical dimension of the insulating islands. Accordingly, the thickness of the conductive layer surrounding the insulating islands may need to be large so as to completely surround the insulating islands with the conductive layer. In summary, in the conventional arrangements, four points may be adjacent to each other, thus causing more diffraction, which can create less well defined corners.

[0088] It will be understood that the upper insulating islands 945I and lower insulating islands 925I can also be unaligned with respect to one another. For example, the upper insulating islands 945I may be arranged in an unaligned array arrangement such as that shown in FIG. 23 and the lower insulating islands 925I can be arranged in an aligned array as shown, for example, in FIG. 8.

[0089] Referring again to FIG. 24, in cases where a probe pin of a tester is applied to the wire bonding region 970, in the direction of the arrow, the applied force of the probe pin of the tester may not be consecutively extended along the lower and upper single bodied conductive plugs 930 and 950 and thus intercepted due to the upper and lower insulating islands 945I and 925I. Accordingly, the resistance to the force (i.e., shear force) of the probe pin may be increased compared to that of the aligned array arrangement shown, for example, in FIG. 8. The spacing D2 between the insulating islands is preferably sufficiently large that cracks occurring in one insulating island do not extend to another insulating island. Preferably, the maximum spacing between the insulating islands is less than twice of the thickness of the conductive material for forming the lower and upper single bodied conductive plugs.

[0090] A solid intermediate interconnection layer 940 in this embodiment can be formed as described in reference to FIG. 8, or it can be formed so that the island insulators are embedded, as described in reference to and as shown in FIG. 12. Thus, the solid intermediate interconnection layer 940 can substantially overlap the upper and lower single bodied conductive plugs 950 and 930, further the solid intermediate interconnection layer 940′ can be congruent to the upper and lower single bodied conductive plugs 950 and 930.

[0091] Pursuant to further embodiments according to the present invention, a bonding pad can include a metal bumper layer 2700 as shown in FIG. 27. The metal bumper layer 2700 is on a an upper connection layer 2760 which is formed on conductive plugs 2750 that are surrounded by insulating material 2745. An upper bonding pad layer 2705 is formed on the metal bumper layer 2700. The upper bonding pad layer 2705 can be directly on the metal bumper layer 2700.

[0092] During fabrication, a test probe may repeatedly contact the upper bonding pad layer 2705, so that portions of the integrated circuit can be tested. Subsequently, a wire can be bonded to the upper bonding pad layer 2705, as shown for example in FIG. 10. The metal bumper layer 2700 can reduce the likelihood that repeated contact of a test probe will reduce the mechanical coupling between the upper conductive plugs 2750 and the upper connection layer 2760. Embodiments according to the present invention may, therefore, increase the reliability of the integrated circuit by reducing the likelihood that the upper connection layer 2760 will become detached from the upper conductive plugs 2750 as a result of repeated contact by the test probe.

[0093] In conventional bonding pad structures, the test probe may erode the upper connection layer so that portions of the upper conductive plugs and the insulating material may be exposed. Solder used to bond the wire to the bonding pad may, therefore, contact the exposed insulating material which may not provide adequate bonding adhesion and thereby cause the upper connection layer to detach from the upper conductive plugs.

[0094] Bonding pad structures according to the present invention can be fabricated by forming a lower connection layer 2740 on a first dielectric layer 2710. The lower connection layer 2740 can be a metal such as aluminum or copper. Other metals can be used. The lower connection layer 2740 is patterned and a second insulating layer 2745, such as an oxide layer, is formed thereon. The second insulating layer 2745 is patterned to form vias therein. The upper conductive plugs 2750 are formed in the vias using a etch back process or Chemical Mechanical Polishing (CMP). The upper conductive plugs 2750 can be a conductive material, such as W, AL, Cu. Other conductive materials can be used. A barrier layer, such as Ti or Tin, (not shown) can be deposited between the lower connection layer 2740 and the second insulating layer 2745.

[0095] A second connecting layer 2760 is formed on the second insulating layer 2745 and the upper conductive plugs 2750. The metal bumper layer 2700 is formed on the second connecting layer 2760 using an etch back process as shown in FIG. 27 or a Chemical Mechanical Polishing (CMP) process as shown in FIG. 28. The metal bumper layer 2700 can be about 4000 Å thick. In some embodiments, the metal bumper layer 2700 can be formed simultaneously with plugs in an internal area of the integrated circuit. The upper bonding pad layer 2705 is formed on the metal bumper layer 2700 to a thickness in a range between about 8000 Å to about 10000 Å. In some embodiments, the combined thickness of the metal bumper layer 2700 and the upper bonding pad layer 2705 is in a range between about 12000 Å to about 14000 Å. As shown in FIG. 28, the thickness of the metal bumper layer 2700 and the upper bonding pad layer 2705 can be adjusted to compensate for the etch back process or the CMP.

[0096] In some embodiments, the metal bumper layer 2700 comprises tungsten. Other metals can be used. It will be understood that the metal bumper layer 2700 can also be formed as part of bonding pad structures that include the spaced apart insulating islands and the single bodied conductive plugs according to the present invention, such as those described in reference to FIGS. 8-22 and FIGS. 23-26.

[0097] FIG. 29 is a cross-sectional view that illustrates embodiments of bonding pad structures having metal bumper layers 2900 with insulating islands 2905 located therein according to the present invention. As shown in FIG. 29, the insulating islands 2905 can be located in the metal bumper layer 2900 and towards the outer edges thereof. Accordingly, an inner region of the metal bumper layer 2900 may have fewer insulating islands 2905 than are located towards the outer edges. In some embodiments, the inner region of the metal bumper layer 2900 is free of insulating islands 2900. Embodiments according to the present invention, may therefore be less susceptible to stress applied to the inner region of the metal bumper layer 2900, and therefore, be less likely to become detached.

[0098] FIG. 30 is a cross-sectional view that illustrates embodiments of bonding pad structures having metal bumper layers 3000 according to the present invention. As shown in FIG. 30, a second conductive layer 3010 and upper conductive plugs 3020 can be formed using a damascene process. The metal bumper layer 3000 and an upper bonding pad layer 3005 upper can be combined into a single layer having a thickness that is in a range between about 12000 Å to about 14000 Å.

[0099] In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.