CN101981225A - 低湿蚀刻速率的氮化硅膜 - Google Patents

低湿蚀刻速率的氮化硅膜 Download PDF

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CN101981225A
CN101981225A CN2008801214068A CN200880121406A CN101981225A CN 101981225 A CN101981225 A CN 101981225A CN 2008801214068 A CN2008801214068 A CN 2008801214068A CN 200880121406 A CN200880121406 A CN 200880121406A CN 101981225 A CN101981225 A CN 101981225A
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flow rate
silicon nitride
nitride film
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赫门特·P·芒吉卡
吴璟
杨·S·李
王安川
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Abstract

本发明是关于利用高密度等离子体化学气相沉积技术,在基板温度低于600℃下沉积低湿蚀刻速率氮化硅膜至基板上的方法。该方法还包括维持等离子体中的氮与硅呈高比例及维持低处理压力。

Description

低湿蚀刻速率的氮化硅膜
发明背景
本发明涉及纳米制造技术解决方案,包括用于沉积、图案化及处理薄膜与涂层的设备、工艺和材料,代表性实例应用包括(但不限于):半导体与介电材料和装置、硅基晶圆、平板显示器(如TFT)、掩模和滤光片、能量转换与储存器(如光伏电池、燃料电池和蓄电池)、固态照明设备(如LED和OLED)、磁光储存器、微机电系统(MEMS)与纳米机电系统(NEMS)、微光学与光电装置、建筑与汽车玻璃、用于金属与聚合物箔及封装的金属化系统、和微成型与纳米成型。较特别地,本发明涉及将薄膜施加于表面上。更特别地,本发明涉及利用化学气相沉积(CVD)形成高密度薄膜的方法。
传统热CVD工艺供应反应气体至基板表面,在此表面的热引发化学反应而产生膜。使用等离子体源促进化学反应可改善沉积速率和膜性质。等离子体增强化学气相沉积(PECVD)技术通过将射频(RF)能量施加到基板表面附近的反应区而产生等离子体,从而促使反应气体激发、离解及离子化。等离子体中的高反应性物种会降低活化化学反应所需的能量。相较于传统热CVD工艺,这有效地降低了PECVD工艺所需的基板温度。降低基板温度是有益的,因其可减少发生可能导致制造工艺产率降低的扩散或其它大量传输(masstransport)作用的机会。
利用高密度等离子体(HDP)CVD技术可进一步加以改善,其中密集等离子体在低真空压力下形成,因此等离子体物种更具反应性。HDP-CVD能采用较低的反应气体分压,同时维持高离子浓度。HDP-CVD也能与离子化能量无关地独立控制加速能量。除了与图案化晶圆处理相关的特点外,利用高密度等离子体沉积膜还有一些材料变化。以HDP-CVD方法沉积的薄膜的密度比用其它CVD方法高。较密集薄膜展现更好的均匀性(homogeneity),并更适合做为蚀刻或研磨终止层。
集成装置制造常用的材料为氮化硅。氮化硅膜用于集成电路前端处理工艺的两种常规应用包括在精密的集成装置周围形成间隔物结构及在金属前介电层(premetal dielectric layer)与半导体基板之间形成接触蚀刻终止层(如阻挡层)。当作为蚀刻终止层时,理想的是,在氧化硅蚀刻工艺期间,此膜具有呈低湿蚀刻速率(WER)的能力。
氮化硅膜内存有杂质常常与高蚀刻速率有关而降低做为蚀刻终止的效用。易并入生长的氮化硅膜的一种杂质为氢。以传统热CVD方法生长氮化硅已成功地减少其氢含量至10%以下,然而,此化学气相沉积的基板温度在700℃至1000℃的范围内。高温会降低、甚至破坏材料性质和先前处理步骤形成的装置。
因此,此技术仍需在低沉积温度下沉积低WER氮化硅膜至基板上的方法。
发明内容
本发明是关于利用HDP-CVD工艺,在低沉积温度下沉积高质量氮化硅膜至基板上的方法。在一些实施例中,平均基板温度低于或约为600℃;在其它实施例中,平均基板温度处于500℃或450℃、或者低于500℃或450℃。
根据本发明的一实施例,利用HDP-CVD工艺,沉积氮化硅膜至处理腔室内的基板上的方法包含将含氮与硅的处理气体混合物流入处理腔室中,同时维持氮原子流率与硅原子流率的平均比率为约50∶1或更大、维持处理腔室内的平均压力为约40毫托或更小、以及维持平均基板温度为约600℃或更低。高密度等离子体由处理气体产生,用以沉积氮化硅膜至基板上。在其它实施例中,氮原子流率与硅原子流率的平均比率大于或等于60∶1或90∶1,处理腔室内的平均压力为25毫托或以下、15毫托或以下、10毫托或以下、或5毫托或以下。处理气体混合物可包括双原子氮(N2)和甲硅烷(SiH4),但也可使用乙硅烷(Si2H6)和三硅胺(N(SiH3)3;TSA)、或其它适合的气体混合物。本发明的制造方法可以以大于约500埃/分钟
Figure BPA00001160599300021
的速率来沉积氮化硅膜,使用氢氟酸溶液(1%HF水溶液)处理时,沉积膜的湿蚀刻速率可以小于
Figure BPA00001160599300022
相较于传统HDP沟填沉积(gapfill deposition)工艺,本发明的一些实施例在沉积时施加少许或不施加RF偏压功率,在不同实施例中,膜生长期间的沉积与溅射比率大于或等于50∶1、75∶1或100∶1。再者,在一些实施例中,沉积期间引进氩气流至处理腔室中,以促进高密度等离子体形成。氮原子流率与氩原子流率的比率可以维持在15∶1与15∶2之间,施加来产生高密度等离子体的RF功率可以为在每平方厘米5瓦与15瓦之间(5-15瓦/平方厘米)。
本发明的上述和其它实施例将进一步详述于后附的说明书其余部分和附图中。
附图说明
图1为部分完成的集成装置的局部截面图,装置制造受益于使用根据本发明一实施例生长的低湿蚀刻速率(WER)氮化硅膜;
图2为根据本发明一实施例,形成高密度且高抗氧化物蚀刻性的氮化硅膜的步骤流程图;
图3为RBS-HFS材料分析系统的示意图,用于测定氢含量;
图4为根据实施例改变N2∶SiH4气流比率所生长的氮化硅膜的湿蚀刻速率曲线图;
图5为根据实施例改变处理腔室压力所生长的氮化硅膜的湿蚀刻速率曲线图;
图6A为可施行本发明的方法的高密度等离子体化学气相沉积系统的一个实施例的简化示意图;以及
图6B为可与图6A的示例处理系统一起使用的气环的简化截面图。
具体实施方式
本发明涉及形成利用高密度等离子体CVD技术沉积的高质量氮化硅膜的方法。当二者接触同样的蚀刻剂时,高质量膜的WER比氧化硅低。通过减少氢含量可获得低WER。在不同实施例中,氮化硅膜的氢含量可以少于10%或可以少于7%。根据本发明的技术能沉积氢含量少的氮化硅膜,同时在沉积期间维持基板温度呈相对低温(<600℃)。
许多受惠于具高密度、低湿(或干)氧化物蚀刻速率、高介电常数、高光学折射率和其它相关物理特性的氮化硅膜的应用,会受惠于本发明各实施例的使用。
以先前CVD技术制得的氮化硅膜中的主要杂质为氢,其通常是处理气体混合物中的氢气留下所致。减少留在氮化硅膜中的氢可增加膜密度及提高氧化物蚀刻的氧化物/氮化物选择性。换句话说,密度增加可提升氮化硅膜的抗蚀能力一段时间,期间没有露出氮化硅的区域遭连续侵蚀。
举例来说,高密度动态随机存取存储器(DRAM)的制造采用电容器来储存信息。每个电容器需有一定阈值水平的电容,以于各刷新周期(refresh cycle)之间储存电荷。每个装置缩小对保持该阈值水平而言是一大挑战。一电容器结构涉及制造更高的圆柱,以补偿其在每个装置缩小中必须制作得更薄的情况。此种电容器形状易产生侧向偏移而降低产率。
金属连接制作在电容圆柱底下时,此工艺称为电容器覆位线(COB;capacitor over bit line)结构。氮化硅层可从上面支撑做为称作实际无限高的机械增强储存节点(MESH;mechanically enhanced storage node for vietually unlimitedheight)的结构。氮化硅MESH用来防止侧向偏移。图1显示此制造方法。移除氧化硅区域108时,电容器104未遭湿氧化物蚀刻。氮化硅层114的蚀刻速率期望比氧化硅区域108慢,使氮化物层得以防止湿氧化物蚀刻剂侵蚀构成电容器的介电层。因此,本发明的方法可用于制造采用图1所示结构的DRAM装置。
本发明的方法和技术不限于制造DRAM。其也可应用到其它蚀刻终止层(ESL),包括置于栅材料(如多晶硅)或金属前电介质(PMD)之上的蚀刻终止层。更广泛地说,本发明实施例将有益于任何可能受惠于低基板沉积温度和具有高抗氧化物蚀刻步骤能力的膜的应用。此外,光波导通过使用高折射率的密集膜而增大局限。由于所述沉积技术能采取较低的基板温度,所以倘若与芯片上电子装置整合,则特别适合光学应用。
在实施例中,等离子体激发为高密度等离子体,其可通过电感耦合(inductive coupling)产生。其它类型的等离子体源也可单独使用或与感应等离子体结合。使用高密度等离子体在选择处理气体方面有较大的灵活性。可使用非常惰性的气体,例如氮气做为HDP工艺的氮(N)源,而氨气(NH3)更常做为低密度PECVD工艺的氮源。
在此,高密度等离子体工艺为一种等离子体CVD工艺,其采用等离子体的离子密度达1011离子数/立方厘米或以上、离子化比例(离子/中性比)达10-4或以上。HDP-CVD工艺一般包括同时沉积及溅射组分。本发明实行的HDP-CVD工艺与传统的适合沟填的HDP-CVD工艺略有不同。在一些实施例中,施加实质微小或不施加偏压功率来形成高密度氮化硅膜,如此溅射程度比施加显著偏压功率以促进溅射的HDP-CVD工艺少。尽管这背离了传统的HDP-CVD工艺参数,然而溅射与沉积速率相关的特征仍是有帮助的,因此将在下面的描述中定义它。
高密度等离子体沉积和溅射特性的相对结合量可以视用于提供气体混合物的气体流率、施加来维持等离子体的源功率大小、施加至基板的偏压功率大小等而定。这些因素的结合可适当量化成“沉积/溅射比率”,有时以D/S表示来描述工艺特征。
Figure BPA00001160599300051
沉积/溅射比率随沉积增加而提高,且随溅射增加而降低。在D/S定义中,“净沉积速率”是指同时发生沉积及溅射时测量的沉积速率。“毯覆溅射速率(blanket sputtering rate)”是在无沉积气体的情况下进行工艺配方(processrecipe)、处理腔室内的压力调整成沉积期间的压力时测量的溅射速率,并且是在毯覆热氧化物上测量的溅射速率。
如本领域的普通技术人员所知的,其它类似测量也可用来定量HDP工艺中沉积及溅射的相对贡献度。另一常用比例为“蚀刻/沉积比率”。
Figure BPA00001160599300052
其随溅射增加而提高,且随沉积增加而降低。在E/D定义中,“净沉积速率”是指同时发生沉积及溅射时测量的沉积速率。“仅有来源的沉积速率”是指无溅射的情况下进行工艺配方时测量的沉积速率。本发明实施例在此是采用D/S比率。虽然D/S和E/D并非恰为倒数,但它们是反向关联的(inverselyrelated),本领域的技术人员应当理解二者之间的转换。
典型的HDP-CVD工艺适合进行几何结构的沟填。在这些工艺中,偏压功率用来加速离子往形成窄范围接近轨迹的生长表面前进。结合溅射作用的窄化造成在封闭通孔顶部转角而形成空隙前填充一些间隙。沟填应用的D/S比率通常在3至10的范围内,一些奇特应用的D/S比率甚至超过25。本发明的一实施例涉及利用HDP-CVD工艺并施加少许或不施加偏压功率来形成高密度氮化硅膜。这些条件下的毯覆溅射速率很低且难以测量,然而D/S比率通常预期会在约100以上。
为了更好地理解本发明,请参照图2,其为根据本发明的一实施例,形成高密度且高抗氧化物蚀刻性的氮化硅膜的步骤流程图。这些步骤将在后面详细描述,在此先概略说明。如图2所示,将基板传送到由真空泵排空的处理腔室(步骤204)。在流入气体前、后或期间(步骤212、216),施加功率至等离子体源(步骤208),并且持续开启直到停止流入气体前、后或期间(步骤226、230)。在步骤212中,输送前驱气体和流动气体(fluent gas)(图2中未示出)至反应区,以形成处理气体混合物。处理气体混合物提供氮与硅源,以在基板上形成氮化硅膜(步骤220)。前驱气体可以包括含硅气体(如甲硅烷(SiH4))和含氮(N)气体(如氮分子(N2))。其它气体也可使用。可采用包含硅与氮的分子做为一或多个前驱气体。
一般而言,硅源和氮源经由不同的输送通道引入,使其在反应区或附近混合。流动气体亦可引入用来协助处理气体混合物的其它组分产生离子物种。例如,氩气比N2更易被离子化,在一实施例中,其为等离子体提供电子而促进N2离解及离子化。此作用提高了化学反应的可能性和沉积速率。流动气体可经由与硅源或氮源相同或不同的输送通道引入。
本发明的实施例维持高氮(N)与硅(Si)原子流比率,以降低氮化硅膜的氢浓度。实质上,氮原子有助于从生长氮化硅网络中清除氢。在一实施例中,气流比率为在25∶1与40∶1(N2∶SiH4)之间,或更广泛地说,原子流比率为在50∶1与80∶1(N∶Si)之间时,从HFS的直接测量结果和WER的间接测量结果可发现氢含量减到最少。在不同实施例中,本发明采用的N2∶SiH4比率为25∶1、30∶1、或者45∶1或以上(或相当于N∶Si比率为50∶1、60∶1、或者90∶1或以上),用以使氢并入最少。
原子流比率(N∶Si)是从各前驱气体的流率和每一分子中各原子所占总数计算而得。在前驱物为N2和SiH4的实施例中,每一氮分子包括二个氮原子,而每一甲硅烷只包括一个硅原子。利用质量流量控制器维持气流比率如大于30∶1时,原子流比率将大于60∶1。在另一实施例中,前驱气体包括至少一含氮与硅的气体。计算原子流比率时,所有原子流率的贡献皆已涵盖。
除了N∶Si原子流比率外,氢的最小化还取决于反应前驱物的其它性质。氮气(N2)和三硅胺(N(SiH3)3;TSA)是合适的前驱物,因二分子中的氮(N)均未直接与氢原子键结。前驱气体具有N-H键会妨碍氮原子将氢移出生长膜。因此氨气(NH3)不是适当的氮源。含氧的氮源(如N2O)通过将氧并入网络而恶化氮化硅膜性质,这也将提高湿蚀刻速率。
保持反应区呈低压还有助于维持低氢含量。增加压力会缩短平均自由径(mean free path),进而改变离子化比例和气相动态特性,以及妨碍氢移出氮化硅网络。在不同实施例中,反应区的压力可为40毫托或以下、25毫托或以下、15毫托或以下、10毫托或以下、或者5毫托或以下。
在高流率比下维持低压需使用设有节流阀的大型泵,节流阀为完全或几乎完全打开以达到最小WER时的适当生长速率。泵的抽吸能力视腔室体积与结构和气流比等因素而定。若本发明用于应用材料公司制造的Ultima HDP室和300毫米(mm)晶圆,则抽吸速度大于或等于2800升/秒(liter/sec)可获得600埃/分钟
Figure BPA00001160599300071
的最佳膜的生长速率。本发明实施例采用美国专利号7,183,227、名称为“Use of Enhanced Turbomolecular Pump for Gapfill DepositionUsing High Flows of Low-Mass Fluent Gas”中所述的抽吸构造,在此引述其内容作为参考。采取较快的抽吸速度或使WER大于根据本发明实施例最佳化的值,可获得较快的生长速率。
在不同实施例中,基板温度维持为约600℃或以下、500℃或以下、或450℃或以下。施加至处理腔室顶部和侧边的RF功率在反应区产生等离子体,其将在后面详细描述。顶部RF功率一般小于侧边RF功率,就300mm晶圆来说,总体RF功率介于4000瓦与10000瓦之间(5瓦/平方厘米(watts/cm2)与15瓦/平方厘米之间)。在不同实施例中,总体RF功率为在约5瓦/平方厘米与15瓦/平方厘米之间,或在约5.5瓦/平方厘米与10瓦/平方厘米之间。在一实施例中,用来加速离子往晶圆前进的偏压RF功率为0或近似0。然而在不同实施例中,若偏压功率开启且相较于其它RF功率总和维持在低或最小功率使沉积与溅射比率在约50、75或100以上,则本发明实施例的许多优势仍在。
在本发明的一实施例中,将基板传送到沉积腔室(步骤204)。(步骤208)开始产生等离子体而步骤212流入含氮前驱物。进行步骤208和212后,流入含硅前驱物(步骤216)及开始生长膜(步骤220)。接着在流入含氮前驱物(步骤230)及中止等离子体(步骤238)前,停止流入含硅前驱物(步骤226)。在一些实施例中,理想的是在停止流入氮前驱物前先停止流入硅前驱物,使得N∶Si原子流比率至少维持像膜生长(步骤220)期间一样高。如此维持高N∶Si原子流比率可避免生长工艺结束时形成可能具有高氢含量和低WER的氮化硅薄层。理想的是在执行特征描述(characterization)步骤时仅探测外面数个单层。若最后数个单层具有不同物理特性,则体性质(bulk property)的推测可能有误。还理想的是,整个膜保持低湿蚀刻速率,以膜如做为蚀刻终止的利用性最大。在一实施例中,当存有含硅前驱物时,确保等离子体含有充足的氮可获得实质均匀的低湿蚀刻速率。
在另一实施例中,开始产生等离子体前先流入氮。同样地,在流入含氮前驱物前,中止等离子体。中止流入含氮前驱物及中止等离子体后,可以将晶圆移出沉积腔室(步骤244)。也可进行图2未示出的其它步骤,包括流入及终止流入流动气体来提高等离子体密度,但不以此为限。在又一实施例中,步骤226与步骤230间可以开始流入惰性物种及增加惰性物种流量并可减少氮流量。
本领域技术人员所熟知的氢前向散射光谱仪(HFS;Hydrogen ForwardScattering spectroscopy)和傅立叶变换红外线光谱仪(FTIR;Fourier TransformInfrared spectroscopy)用来定量膜的氢含量。HFS对低浓度氢的灵敏度相当高并更可靠。实验条件列于表I和图3。HFS定量探测测试沉积膜的散射氢(H),并与得自特征化的白云母样品的结果相比。接着以百分比表示氢含量。多个He++氦剂用来确保氢浓度在测试期间不会下降。也可采用傅立叶变换红外线光谱仪(FTIR)的更传统的技术,但灵敏度较低。
表I:氢前向散射(HFS)的实验条件
Figure BPA00001160599300081
为证实本发明一些实施例的优点,实验比较根据这里所述的技术沉积的HDP-CVD氮化硅膜和以PECVD与LPCVD方法沉积的氮化硅膜的WER与氢含量。在装配300mm基板的Ultima HDP室内处理基板,氮化硅膜生长期间的抽吸速度为2800升/秒。HDP-CVD沉积期间的基板温度维持为约450℃,施加至顶部和侧边的等离子体RF功率为2000瓦和3000瓦。生长期间不施加偏压功率。硅烷气体流率为40sccm,氮气流率为1500sccm,氩气流率为300sccm。
除了直接从HFS测定残余氢含量外,还可测定WER来测量膜的耐化学性。分别于氢氟酸(1%HF水溶液)蚀刻前后,测量氮化硅膜的厚度。在25℃下持续进行湿蚀刻工艺一段时间后,计算蚀刻速率。膜的分析结果列于表II的HDP栏。现有技术的结果列于其它栏以供比较。1%HF水溶液蚀刻热生长氧化硅的速率为36埃/分钟
Figure BPA00001160599300091
表II:膜特征vs.沉积技术
Figure BPA00001160599300092
图4显示在SiH4流率固定为40sccm的情况下,随N2气体流率变化的湿蚀刻速率。N2气体流率较低时,湿蚀刻速率会先下降,这是因为工艺的氮源受限。在此区域中,添加额外的氮至等离子体中能更有效地在生长期间移除膜中的氢。湿蚀刻速率接着达到最小值,然后因腔室压力增加而开始上升。膜制备期间的抽吸速度保持不变。压力升高时,等离子体中的气体动态特性改变,导致降低氮移除氢的能力。该工艺显示当N2∶SiH4流率比率为约25∶1时,WER明显改善,流率比率为25∶1至40∶1之间达到最小值,然后因抽吸限制开始上升。
不同抽吸速度会改变WER急剧上升408的位置及可以改变WER的最小值418。假设有效抽吸速度从2800升/秒提高成4000升/秒,则图4的WER急剧上升位置将从50∶1周围移到70∶1附近。这一改变可改善膜生长速率和/或WER。按恒定气流比率增加气体流率可提高膜生长速率。同样地,按恒定硅烷气体流率增加N2∶SiH4气流比率可进一步降低WER。
图5显示在固定的N2(1500sccm)和SiH4(40sccm)流率的情况下,随腔室压力变化的湿蚀刻速率。通过改变节流阀位置,进而改变有效抽吸速度,可改变压力。随着腔室压力上升,膜质量显然会降低(湿蚀刻速率提高),原因如同参考图4的描述所述。提高抽吸速度可改善膜质量。
示例性基板处理系统
本发明利用位于美国加州圣克拉拉的应用材料公司(Applied Materials,Inc.)制造的ULTIMATM系统来实践本发明实施例,其概述于共同受让的美国专利号6,170,428、名称“SYMMETRIC TUNABLE INDUCTIVELY COUPLEDHDP-CVD REACTOR”、1996年7月15日申请、Fred C.Redeker、FarhadMoghadam、Hirogi Hanawa、Tetsuya Ishikawa、Dan Maydan、Shijian Li、BrianLue、Robert Steger、Yaxin Wang、Manus Wong和Ashok Sinha提出的申请案,其全文在此一并引入作为参考。该系统将结合图6A及6B概述于下。图6A为HDP-CVD系统610的一实施例的结构示意图。系统610包括腔室613、真空系统670、源等离子体系统680A、偏压等离子体系统680B、气体输送系统633和远程等离子体清洁系统650。
腔室613的上部包括圆顶614,其由陶瓷介电材料构成,例如氧化铝或氮化铝。圆顶614界定等离子体处理区616的上边界。等离子体处理区616的底部以基板617的上表面和基板支撑构件618为界。
加热板623和冷却板624装在圆顶614上且热耦接至圆顶614。加热板623和冷却板624能控制圆顶温度在约(100℃至200℃)±10℃的范围内。这样可最佳化圆顶温度以进行不同工艺。例如,理想的是,清洁或蚀刻工艺的圆顶温度大于沉积工艺。准确控制圆顶温度还能减少腔室内的剥落薄片或微粒数及改善沉积层与基板间的附着性。
腔室613的下部包括主体构件622,其连结腔室和真空系统。基板支撑构件618的基部621装在主体构件622上,并且一起构成连续的内表面。机械叶片(未示出)经由腔室613侧边的插入/移出开口(未示出)传送基板进出腔室613。举升销(未示出)在马达(未示出)的控制下升起及下降,从而将机械叶片上的基板从上部装载位置657移到较低处理位置656,在此基板放置到基板支撑构件618的基板接收部619。基板接收部619包括静电卡盘620,以在基板处理期间让基板固定到基板支撑构件618。在一优选实施例中,基板支撑构件618由氧化铝或铝陶瓷材料构成。
真空系统670包括用来容纳双叶片节流阀626的节流主体625,并且连接到闸阀(gate valve)627和涡轮分子泵628。应注意节流主体625最小程度地阻碍气流且容许对称抽吸。闸阀627能够隔开泵628和节流主体625,还能通过限制节流阀626完全打开时的排气流量来控制腔室压力。配设节流阀、闸阀和涡轮分子泵可精确及稳定地控制腔室压力高达约1毫托至约2托。
源等离子体系统680A包括设于圆顶614的顶部线圈629和侧边线圈630。对称接地屏蔽(未示出)可减少线圈间的电性耦合。顶部线圈629由顶部源射频(SRF)发生器631A供电,侧边线圈630由侧边SRF发生器631B供电,使得各线圈有独立的功率大小和操作频率。双线圈系统可控制腔室613内的径向离子密度,进而改善等离子体均匀度。侧边线圈630和顶部线圈629一般为感应驱动,其不需使用互补电极。在一特定实施例中,顶部源RF发生器631A以额定的2MHz供应高达2500瓦的RF功率,侧边源RF发生器631B以额定的2MHz供应高达5000瓦的RF功率。顶部和侧边RF发生器的操作频率可偏离额定操作频率(如分别为1.7-1.9MHz和1.9-2.1MHz),从而改善等离子体产生效率。
偏压等离子体系统680B包括偏压RF(BRF)发生器631C和偏压匹配网络632C。偏压等离子体系统680B电容耦合基板部分617和主体构件622,其当作互补电极。偏压等离子体系统680B用来加强输送源等离子体系统680A产生的等离子体物种(如离子)至基板表面。在一特定实施例中,偏压RF发生器以小于5MHz的频率供应高达10000瓦的RF功率,其将在后面进一步说明。
RF发生器631A和631B包括数字控制合成器且操作频率介于约1.8至约2.1MHz之间。如同本领域的普通技术人员所理解的,每一发生器包括RF控制电路(未示出),用以测量从腔室和线圈反射回发生器的功率,以及调整操作频率而获得最小反射功率。RF发生器一般设计为操作成特征阻抗为50欧姆的负载。RF功率可从具有不同特征阻抗的负载反射回发生器。如此可减少传送到负载的功率。此外,从负载反射回发生器的功率可能过载而破坏发生器。由于等离子体的阻抗范围可在从小于5欧姆至大于900欧姆,视等离子体离子密度等因素而定,又由于反射功率可以为频率的函数,因此依据反射功率调整发生器频率可增加从RF发生器传送到等离子体的功率及保护发生器。另一减少反射功率及提高效率的方式为利用匹配网络。
匹配网络632A和632B匹配发生器631A和631B的输出阻抗和其对应线圈629和630。RF控制电路可以通过改变匹配网络内的电容值来调整二匹配网络,使发生器随负载变化而与负载匹配。当从负载反射回发生器的功率超过一定极限时,RF控制电路可调整匹配网络。提供固定匹配以及有效地使RF控制电路失去调整匹配网络的能力的方式为设定反射功率极限大于任一反射功率预定值。保持匹配网络固定处于其最新条件有助于在一些条件下稳定等离子体。
其它测量也可以有助于稳定等离子体。例如,RF控制电路可用来测定传送到负载(等离子体)的功率,及提高或降低发生器输出功率,以在沉积层期间维持传送功率实质不变。
气体输送系统633经由气体输送管线638(仅示出部分)提供来自数个源634A-634E的气体给腔室来处理基板。如同本领域的普通技术人员所熟知的,用于源634A-634E的实际源和输送管线638与腔室613的实际连接视腔室613内所执行的沉积和清洁工艺而定。气体经由气环637和/或顶部喷嘴645引进腔室613。图6B为腔室613的简化局部截面图,其示出气环637的细节。
在一实施例中,第一与第二气源634A、634B和第一与第二气体流量控制器635A’、635B’经由气体输送管线638(仅示出部分)供应气体至气环637的环形气室636。气环637设有多个源气体喷嘴639(仅示出其中一个以便于说明),用以提供遍及基板的均匀气流。可以改变喷嘴长度和喷嘴角度,以调整个别腔室内的均匀度分布轮廓和特定工艺的气体利用率。在一优选实施例中,气环637设有12个由氧化铝陶瓷构成的源气体喷嘴。
气环637还设有多个氧化气体喷嘴640(仅示出其一),在一优选实施例中,其与源气体喷嘴639呈共平面且比源气体喷嘴639短,在一实施例中,其接收来自主体气室641的气体。在一些实施例中,理想的是,气体注入腔室613前,不先混合源气体和氧化气体。在其它实施例中,气体注入腔室613前,可以先利用主体气室641与气环气室636间的孔洞(未示出)混合氧化气体和源气体。在一实施例中,第三、第四与第五气源634C、634D、634D’和第三与第四气流控制器635C、635D’经由气体输送管线638供应气体至主体气室。附加阀如阀643B(其它阀未示出)可关闭气体从流量控制器流向腔室。在执行本发明的一些实施例中,源634A包含甲硅烷SiH4源,源634B包含氮分子N2源,源634C包含TSA源,源634D包含氩Ar源,源634D’包含乙硅烷Si2H6源。
在使用易燃、有毒或腐蚀性气体的实施例中,理想的是,在沉积后清除残留在气体输送管线中的气体。实现方式可以例如为利用三通阀(如阀643B)来隔开腔室613和输送管线638A,及排放输送管线638A至真空前段管线644。如图6A所示,其它类似阀(如阀643A、643C)可设于其它气体输送管线。三通阀可尽量设置靠近腔室613,以减少未排放的气体输送管线体积(位于三通阀与腔室之间)。此外,双向(开-关)阀(未示出)可设在质量流量控制器(MFC)与腔室之间、或气源与MFC之间。
再次参照图6A,腔室613还设有顶部喷嘴645和顶部排气孔646。顶部喷嘴645和顶部排气孔646能独立控制顶部和侧边的气流以改善膜的均匀度,及微调膜的沉积和掺杂参数。顶部排气孔646为围绕顶部喷嘴645的环状开口。在一实施例中,第一气源634A供给源气体喷嘴639和顶部喷嘴645。源喷嘴MFC 635’控制输送到源气体喷嘴639的气体量,顶部喷嘴MFC 635A控制输送到顶部喷嘴645的气体量。同样地,两个MFC 635B和635B’可以用来控制自单一氧气源(如源634B)流向顶部排气孔646和氧化气体喷嘴640的氧气量。在一些实施例中,不从任一侧边喷嘴供给腔室氧气。供应给顶部喷嘴645和顶部排气孔646的气体在流入腔室613前可保持分开,或者气体流入腔室613前可先在顶部气室648混合。独立分开的相同气源也可用来供给腔室的不同区域。
远程微波产生的等离子体清洁系统650用来定期清洁腔室组件的沉积残余物。清洁系统包括远程微波产生器651,其由清洁气源634E(如氟分子、三氟化氮、其它碳氟化合物或等同物)在反应器腔体653内产生等离子体。等离子体产生的反应物种通过器具管655经由清洁气体入口654输送到腔室613。用来容纳清洁等离子体的材料(如腔体653和器具管655)必须能抵抗等离子体侵蚀。反应器腔体653与入口654间的距离应尽量短,因为理想的等离子体物种的浓度会随着远离反应器腔体653而降低。在远程腔体中产生清洁等离子体允许使用高效率微波产生器,且腔室组件不会受温度、辐射或等离子体中原位形成的辉光放电撞击的影响。因此,不像原位等离子体清洁工艺,诸如如静电卡盘620之类的较敏感的组件不需覆盖有仿制(dummy)晶圆或以其它方式保护。在图6A中,等离子体清洁系统650位于腔室613上方,然而其也可设在其它位置。
隔板661可以设置为邻接顶部喷嘴,用以引导顶部喷嘴供应的源气体流入腔室及引导远程产生等离子体流动。顶部喷嘴645供应的源气体经由中央通道662导向腔室,清洁气体入口654供应的远程产生的等离子体物种由隔板661引至腔室613旁。
本领域的普通技术人员将能理解,处理参数会因处理腔室和处理条件不同而不同,在不悖离本发明的精神的前提下也可使用不同的前驱物。本领域的普通技术人员可明白其它变化例。这些等同例和替代例涵盖在本发明的保护范围内。因此本发明的保护范围不应以实施例为限,而是视后附的申请专利范围所界定的为准。

Claims (25)

1.一种利用一高密度等离子体化学气相沉积工艺沉积一氮化硅膜至一处理腔室中的一基板上的方法,该方法包含:
将一包含氮与硅的处理气体混合物流入该处理腔室中,同时维持该氮原子流率与该硅原子流率的一平均比率为约50∶1或更大,维持该处理腔室中的一平均压力为约40毫托或更小,以及维持一平均基板温度为600℃或更低;以及
从该处理气体形成一高密度等离子体以沉积该氮化硅膜至该基板上。
2.根据权利要求1所述的方法,其中该氮原子流率与该硅原子流率的平均比率为约60∶1或更大。
3.根据权利要求1所述的方法,其中该氮原子流率与该硅原子流率的平均比率为约90∶1或更大。
4.根据权利要求1所述的方法,其中该平均基板温度维持在500℃或以下。
5.根据权利要求1所述的方法,其中该处理腔室中的该平均压力为约15毫托或更小。
6.根据权利要求1所述的方法,其中使用一氢氟酸溶液(1%HF水溶液)处理沉积的氮化硅膜的一湿蚀刻速率小于5埃/分钟
Figure FPA00001160599200011
7.根据权利要求1所述的方法,其中沉积的氮化硅膜的一生长速率大于约500埃/分钟
Figure FPA00001160599200012
8.根据权利要求1所述的方法,进一步包含将氩气流入该处理腔室中,以及维持该氮原子流率与该氩原子流率的一比率为在15∶1与15∶2之间。
9.根据权利要求1所述的方法,其中该高密度等离子体的一RF功率为在每平方厘米基板表面5与15瓦之间。
10.根据权利要求1所述的方法,其中该高密度等离子体的一RF功率为在每平方厘米基板表面5.5与10瓦之间。
11.根据权利要求1所述的方法,其中形成该高密度等离子体的步骤在沉积该氮化硅膜期间不朝向该基板偏压该等离子体。
12.根据权利要求1所述的方法,其中该高密度等离子体化学气相沉积工艺的一沉积与溅射比率大于约50∶1。
13.根据权利要求1所述的方法,其中该处理气体混合物包含双原子氮(N2)和至少一选自甲硅烷(SiH4)、乙硅烷(Si2H6)和三硅胺(N(SiH3)3;TSA)组成的群组的气体。
14.一种利用一高密度等离子体化学气相沉积工艺沉积一氮化硅膜至一处理腔室中的一基板上的方法,该方法包含:
以一第一气体流率将双原子氮(N2)流入该处理腔室中并以一第二气体流率将甲硅烷(SiH4)流入该处理腔室中,同时维持该第一气体流率与该第二气体流率的一平均比率为约25∶1或更大,维持该处理腔室中的一平均压力为约40毫托或更小,以及维持一平均基板温度为600℃或更低;以及
从该处理气体形成一高密度等离子体以沉积该氮化硅膜至该基板上。
15.根据权利要求14所述的方法,其中该第一气体流率与该第二气体流率的平均比率为约30或更大。
16.根据权利要求14所述的方法,其中该第一气体流率与该第二气体流率的平均比率为约40或更大。
17.根据权利要求14所述的方法,其中该平均基板温度维持在500℃或以下。
18.根据权利要求17所述的方法,其中该处理腔室中的该平均压力为约15毫托或更小。
19.根据权利要求18所述的方法,其中使用一氢氟酸溶液(1%HF水溶液)处理沉积的氮化硅膜的一湿蚀刻速率小于5埃/分钟
Figure FPA00001160599200031
20.根据权利要求18所述的方法,其中沉积的氮化硅膜的一生长速率大于约500埃/分钟
Figure FPA00001160599200032
21.根据权利要求18所述的方法,进一步包含以一第三气体流率将氩气流入该处理腔室中,同时维持该第一气体流率与该第三气体流率的一比率为在15∶2与15∶4之间。
22.根据权利要求18所述的方法,其中该高密度等离子体的一RF功率为在每平方厘米基板表面5与15瓦之间。
23.根据权利要求18所述的方法,其中该高密度等离子体的一RF功率为在每平方厘米基板表面5.5与10瓦之间。
24.根据权利要求18所述的方法,其中形成该高密度等离子体的步骤在沉积该氮化硅膜期间不朝向该基板偏压该等离子体。
25.根据权利要求18所述的方法,其中该高密度等离子体化学气相沉积工艺的一沉积与溅射比率大于约50。
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US7678715B2 (en) 2010-03-16
EP2238277A2 (en) 2010-10-13
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