Process for excavating trenches with a rounded bottom in a silicon substrate for making trench isolation structures

Claim 1

A process for making an encased isolation structure for an integrated semiconductor device having the configuration of a trench, excavated on the surface of a semiconducting substrate of a first conductivity type around active areas of the front of the device and filled with a dielectric material, said semiconducting substrate having been previously covered by a multilayer composed of a first oxide layer, a second layer of a diffusion resistant material superimposed thereto, and a third or top layer of oxide which is thicker than the first oxide layer; characterized by comprising the following steps: a) masking with a photoresist by a photolithographic process active areas on the front of the device; b) anisotropically etching by means of a RIE process said three layers until exposing the surface of the underlying semiconducting substrate in the unmasked area and removing the residual masking photoresist; c) conformably depositing a fourth oxide layer; d) anisotropically etching by means of a RIE process said conformably deposited fourth layer of oxide until exposing the surface of the underlying semiconducting substrate in a central, self-aligned area of said unmasked area, and leaving a tapered residue of said conformably deposited fourth layer of oxide on vertical etch walls of said three layers etched during the preceding step b); e) isotropically plasma etching said semiconducting substrate through said exposed central, self-aligned area until forming a trench having a desired depth and causing a lateral under-cut roundly extending below the base of said tapered residue of said conformably deposited fourth oxide layer; f) removing the residual exposed oxide belonging to said third layer and to said fourth layer; g) implanting on the etched trench surface a dopant of the same conductivity type as the semiconducting substrate for increasing the doping level of the semiconductor material adjacent to the etched trench surface by utilizing said second layer of diffusion impervious materials as a mask; h) thermally growing a thin layer of oxide over the etched and implanted surface of the trench formed in the semiconducting substrate, by utilizing said second layer of diffusion impervious material as a mask; i) removing said second layer of diffusion impervious material; j) depositing a layer of dielectric material until completely filling the trench formed in the semiconducting substrate.