CN112242296A - 形成拓扑受控的无定形碳聚合物膜的方法 - Google Patents
形成拓扑受控的无定形碳聚合物膜的方法 Download PDFInfo
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Abstract
一种在衬底的图案化凹部上形成拓扑受控的层的方法,其包括:(i)通过脉冲等离子体辅助沉积在衬底的图案化凹部上沉积具有填充能力的无Si含C膜以以自下而上的方式或无底方式填充凹部;和(ii)对凹部中填充的自下而上或无底的膜进行等离子体灰化以以主要或基本上仅留下填充膜的底部部分或者主要或基本上仅留下填充膜的侧壁部分的方式去除填充膜的顶部部分。
Description
技术领域
本发明总体上涉及一种在衬底的图案化凹部上形成拓扑受控的无定形碳膜的方法。
背景技术
在制造集成电路如用于浅沟槽隔离、金属间介电层、钝化层等的那些的工艺中,常常有必要用绝缘材料填充沟槽(通常具有为一或更高的纵横比的任何凹部)。然而,随着大规模集成(LSI)装置的布线间距的小型化,由于现有沉积工艺的限制,高纵横比空间(例如,AR≥3)的无空隙填充变得越来越困难。
鉴于上述情况,本发明人开发了用于沉积可流动膜的间隙填充技术并在2018年7月3日提交的美国专利申请号16/026,711中公开了该技术,其在其中不需要氮、氧或氢等离子体的条件下通过使用烃前体的等离子体辅助沉积来提供完全的间隙填充而基本上不形成空隙,该专利申请的公开内容以引用的方式整体并入本文。
然而,如果其中牺牲蚀刻停止层或保护层例如仅在凹部的底部处必要的某些应用需要在衬底的沟槽中使用上述间隙填充技术仅在底部沉积无定形碳,则可能存在以下问题:i)可能会在衬底的顶表面上沉积一定量的膜(虽然量小但不可忽略);ii)取决于每个沟槽的结构体积,在每个沟槽的底部处沉积的膜的量可能不规则(参见图8的(a));和iii)即使每个沟槽的结构体积相似,在间隙填充中也可能存在一些随机性(参见图8的(b))。本发明人在此提供上述问题的解决方案。
在其他应用如3D NAND闪存中,需要超深孔笔直蚀刻。然而,由于在孔蚀刻期间发生侧壁蚀刻,故很难保持笔直的结构,从而导致CD完整性降低。本发明人已发现,上述间隙填充技术可为上述问题提供解决方案。
对相关领域中涉及的问题和解决方案的任何讨论已仅出于为本发明提供背景的目的而包括在本公开内容中,并且不应该视为承认讨论中的任何或全部在制备本发明时是已知的。
发明内容
鉴于上述情况,一些实施例提供了一种在衬底的图案化凹部上形成拓扑受控的层的方法,其包括:(i)通过脉冲等离子体辅助沉积在衬底的图案化凹部上沉积具有填充能力的无Si含C膜以以自下而上的方式或无底方式填充凹部;和(ii)对凹部中填充的自下而上或无底的膜进行等离子体灰化以以主要仅留下填充膜的底部部分或主要仅留下填充膜的侧壁部分的方式去除填充膜的顶部部分。根据以上实施例,通过使用间隙填充技术,可操纵膜的拓扑。膜相对于沟槽大小的流动性程度可主要决定沉积是自下而上的沉积还是无底沉积。
当膜的流动性相对于目标沟槽足够高时,发生自下而上的沉积,并且在完全填充沟槽并在沟槽上方进一步沉积膜之后,通过对膜进行等离子体灰化,沟槽上方膜的顶部部分以及沟槽中填充的膜的上部部分可被同等地去除至沟槽的均匀深度以获得填充了具有深度基本均匀的膜的沟槽。
当膜的流动性相对于目标沟槽足够低时,发生无底沉积;然而,由于膜是可流动的,故即使当膜未到达沟槽的底部并封闭沟槽的上部开口时,膜也可沿着沟槽的侧壁沉积而覆盖侧壁至距离衬底的顶表面一定深度处。在完成膜的沉积之后,通过对膜进行等离子体灰化,可去除封闭沟槽的开口的膜部分以打开沟槽,留下侧壁膜作为间隔物。其后,可进行超深孔笔直蚀刻。由于沟槽的底部基本上未被膜覆盖,并且侧壁膜可保护侧壁使之免于在超深孔笔直蚀刻期间被蚀刻,故蚀刻可在深度方向上进行以形成超深直孔而不降低CD完整性。
出于概述本发明的各方面和所实现的优于相关技术的优势的目的,在本公开中描述本发明的某些目的和优势。当然,应理解,未必所有这些目标或优点都可以根据本发明的任何特定实施例来实现。因此,举例来说,本领域技术人员将认识到,本发明可以按照实现或优化如本文所传授的一个优点或一组优点的方式实施或进行,而不必实现如本文中可能传授或表明的其它目标或优点。
本发明的另外方面、特征和优势将从之后的详细描述变得显而易见。
附图说明
现将参照优选实施例的附图来描述本发明的这些和其他特征,这些优选实施例意图说明而非限制本发明。各图出于说明性目的而被大大简化并且未必按比例。
图1A是可用于本发明的一个实施例中的用于沉积介电膜的PEALD(等离子体增强原子层沉积)设备的示意图。
图1B示意了可用于本发明的一个实施例中的使用流通系统(FPS)的前体供应系统的示意图。
图2为示意根据本发明的实施例进行自下而上的沉积((a)(b)(c))和无底沉积((a)(d)(e))的沟槽的示意性横截面图的图。
图3示出了根据本发明的实施例的沟槽的横截面图的STEM照片,其中:(a)进行自下而上的沉积的沟槽,(b):然后进行O2/Ar灰化的沟槽,(c):或进行N2/H2灰化的沟槽。
图4示出了进行无底沉积(300次循环)而不灰化的沟槽的横截面图的STEM照片的示意图。
图5示出了根据本发明的一个实施例进行无底沉积(300次循环)、然后灰化(90秒)的沟槽的横截面图的STEM照片的示意图。
图6示出了进行无底沉积(350次循环)而不灰化的沟槽的横截面图的STEM照片的示意图。
图7示出了根据本发明的一个实施例进行无底沉积(350次循环)、然后灰化(90秒)的沟槽的横截面图的STEM照片的示意图。
图8示出了进行自下而上的沉积的沟槽的横截面图的STEM照片,其中(a)表示具有不同宽度的沟槽,(b)表示填充了不规则量的膜的沟槽。
图9示出了根据本发明的一个实施例进行自下而上的沉积的沟槽的横截面图的STEM照片,其中(a)表示沉积完成时的沟槽,(b)表示灰化后的沟槽。
图10示出了根据本发明的一个实施例进行自下而上的沉积(完全填充)的沟槽的横截面图的STEM照片,其中原始的(a)表示具有不同宽度(比例尺代表300nm)的宽沟槽和窄沟槽的混合物,原始的(b)表示中等宽度沟槽(比例尺代表60nm),原始的(c)表示宽度略有差异的宽沟槽(比例尺代表60nm),列(1)表示灰化前的完全填充沉积(210次沉积循环)的沟槽,列(2)表示灰化105秒后的沟槽,列(3)表示灰化129秒后的沟槽,列(4)表示灰化165秒后的沟槽。
图11示出了根据本发明的一个实施例进行自下而上的沉积的沟槽的横截面图的STEM照片,其中(a)表示完全填充沉积(210次沉积循环)完成时的沟槽,(b)表示灰化240秒后的沟槽,(c)表示灰化300秒后的沟槽。
图12为示意根据本发明的一个实施例的成膜工艺序列的图,其中灰色的单元格表示开启状态,而白色的单元格表示关闭状态,并且每一列的宽度不代表每个工艺的持续时间。
具体实施方式
在本公开中,取决于上下文,“气体”可包括气化固体和/或液体并可由单一气体或气体的混合物构成。同样,取决于上下文,冠词“一”是指一个物种或包括多个物种的属。在本公开中,通过喷淋头引入到反应腔室的工艺气体可包含无硅烃前体和添加剂气体、基本上由无硅烃前体和添加剂气体组成或由无硅烃前体和添加剂气体组成。添加剂气体可以包括等离子体生成气体,用于在将RF功率施加于添加剂气体时,激发前体以形成无定形碳聚合物。添加剂气体可为惰性气体,其可作为运载气体和/或稀释气体进料到反应腔室。添加剂气体可不含用于氧化或氮化前体的反应气体。或者,添加剂气体可含有用于氧化或氮化前体的反应气体,程度为不干扰等离子体聚合形成基于无定形碳的聚合物。此外,在一些实施例中,添加剂气体仅含有等离子体生成气体(例如,稀有气体)。前体和添加剂气体可以混合气体引入到反应空间或分别引入到反应空间。可利用运载气体如稀有气体引入前体。可使用非工艺气体的气体,即不经过喷淋头而引入的气体,来例如密封反应空间,这包括密封气体,如稀有气体。在一些实施例中,术语“前体”一般指参与产生另一种化合物的化学反应的化合物,并且特别指构成膜基质或膜主要骨架的化合物,而术语“反应物”指除前体外的化合物,其活化前体、修饰前体或催化前体的反应,其中所述反应物可以为膜基质提供元素(例如O、C、N),并且当处于激发态时,变成膜基质的一部分。术语“等离子体生成气体”指除前体和反应物外的化合物,当暴露于电磁能时,所述化合物生成等离子体,其中所述等离子体生成气体可能不为膜基质提供元素(例如O、C、N),所述元素变成膜基质的一部分。术语“等离子体灰化气体”是指当处于直接激发(直接等离子体)或远程激发(远程等离子体)的状态时灰化膜的气体。在一些实施例中,“等离子体灰化气体”为单一气体或者两种或更多种气体的混合气体。术语“灰化”是指使用等离子体去除有机物质,留下矿物组分作为残余物(灰分),其通常用真空泵去除。
在一些实施例中,“膜”是指在垂直于厚度方向的方向上连续延伸的基本上无小孔的覆盖整个目标或相关表面的层,或仅仅是指覆盖目标或相关表面的层。在一些实施例中,“层”是指在表面上形成的具有某一厚度的结构,或膜或非膜结构的同义词。膜或层可由离散的单个具有某些特性的膜或层构成,也可由多个膜或层构成,并且相邻的膜或层之间的边界可能清晰也可能不清晰并可能是基于相邻的膜或层的物理、化学和/或任何其他特性、形成工艺或顺序和/或功能或目的创建的。此外,在本公开中,由于可工作范围可基于常规工作而确定,因此变量的任何两个数字可构成变量的可工作范围,且所指示的任何范围可包括或排除端点。另外,任何所指示的变量值(无论它们是否用“约”指示)都可指精确值或近似值并包括等效值,并且在一些实施例中可指平均值、中位数、代表性值、多数值等。此外,在本公开中,在一些实施例中,术语“由…构成”和“具有”独立地指“典型地或广泛地包括”、“包括”、“基本上由…组成”或“由…组成”。在本公开中,在一些实施例中,任何定义的含义不一定排除普通和惯用的含义。
在本公开中,在一些实施例中,“连续地”指不破坏真空、不随时间轴中断、无任何材料介入步骤、其后不立即改变处理条件作为下一步骤、或者在两个结构之间除了所述两个结构之外无介于之间的离散的物理或化学结构。
在本公开中,术语“填充能力”(也称为“流动性”)是指基本上无空隙(例如,无具有直径大约5nm或更大的尺寸的空隙)或接缝(例如,无具有大约5nm或更长长度的接缝)地填充间隙的能力,其中当在纵横比为约1或更大的宽沟槽中沉积膜时,观察到层的无接缝/无空隙的自下而上生长。
流动性常常在填充沟槽之前在宽沟槽的底部处表现为凹形膜表面,并还在完全填充沟槽之后被连续沉积时表现为基本上平面的膜顶表面(平面化)。这样的沉积被称为“自下而上的沉积”。
当沟槽窄且深时,即使膜是可流动的,膜也可能到达不了沟槽的底部。在这种情况下,流动性常常沿沟槽的侧壁表现为大致或基本上保形的膜,在沟槽的底部处基本上没有膜而沟槽的顶部开口通常被膜封闭。由于膜是可流动的,故侧壁膜流动并沿着侧壁向下延伸,从而形成薄膜,其中膜的基本上保形的部分的平均厚度(除了封闭沟槽的顶部开口的顶部部分外,其随后通过灰化去除)与沟槽中膜的深度(沿着侧壁朝向底部延伸的长度)的比率可在0.1%至10%(通常0.5%至5%)的范围内。这样的沉积被称为“无底沉积”。
在本公开中,邻近的突起结构之间的凹部与任何其他凹部图案被称为“沟槽”。即,沟槽为包含孔/通孔的任何凹部图案。对于自下而上的沉积,在一些实施例中,沟槽具有约20nm至约100nm(通常约30nm至约50nm)的宽度(其中当沟槽具有与宽度基本上相同的长度时,其可被称作孔/通孔)、约30nm至约100nm(通常约40nm至约60nm)的深度以及约2至约10(通常约2至约5)的纵横比。对于无底沉积,在一些实施例中,沟槽具有约5.5nm至约200nm(通常约10nm至约100nm)的宽度(CD)、约800nm至约10,000nm(通常约300nm至约8,000nm)的深度以及约15至约150(通常约20至约100)的纵横比。沟槽的适当尺寸可随工艺条件、膜的流动性、膜组成、既定应用等而异。通过例如调整膜的流动性,可在具有不同于上述那些的尺寸的沟槽中实现自下而上的沉积和无底沉积。
在本公开中,术语“基本上没有沉积”、“基本上没有膜”等是指功能上等价于零的量,无关紧要或可忽略的量,不会实质性干扰后续工艺(例如,灰化)的量,低于可检测量或可观察量的量,等。
在本公开中,在一些实施例中,任何定义的含义不一定排除普通和惯用的含义。而且,在本公开中,“本发明”是指本文明确地、必要地或固有地公开的实施例或方面中的至少一个。
将参照优选实施例来阐述实施例。然而,本发明不旨在局限于这些优选实施例。
一些实施例提供了一种在衬底的图案化凹部上形成拓扑受控的层的方法,其包括:(i)通过脉冲等离子体辅助沉积在衬底的图案化凹部上沉积具有填充能力的无Si含C膜以以自下而上的方式或无底方式填充凹部;和(ii)对凹部中填充的自下而上或无底的膜进行等离子体灰化以以主要仅留下填充膜的底部部分或主要仅留下填充膜的侧壁部分的方式去除填充膜的顶部部分。所述无Si含C膜通常可以是为可流动膜的无定形碳聚合物膜。当通过使用等离子体辅助方法形成无定形碳聚合物膜时,所得的无定形碳聚合物膜由氢化的无定形碳聚合物构成。在本公开中,氢化的无定形碳聚合物可简称为无定形碳聚合物,其也可被称为“aC:H”或简称为缩写“aC”。此外,在本公开中,除非另有说明,否则SiC、SiCO、SiCN、SiCON等等是以非化学计量的方式指示膜类型(简单地由主要构成元素指示)的缩写。
在一些实施例中,在步骤(i)中,使用烃前体沉积无Si含C膜。在一些实施例中,步骤(i)包括:(ia)向放置衬底的反应空间供应前体,和(ib)将衬底的图案化凹部暴露于等离子体以在图案化凹部中沉积无Si含C膜,其中步骤(ib)以脉冲等离子体的方式间歇地进行,并且步骤(ia)作为步骤(ib)的先决步骤连续或间歇地进行,与步骤(ib)无交叠。在一些实施例中,无Si含C膜基本上由烃构成。
可流动膜的沉积是本领域已知的;然而,可流动膜的常规沉积使用化学气相沉积(CVD)伴随RF功率的持续施加,因为脉冲等离子体辅助沉积如PEALD众所周知用于沉积保形膜,所述保形膜是具有与可流动膜的那些完全相反的特征的膜。在一些实施例中,可流动膜是由无定形碳聚合物构成的无硅含碳膜,并且尽管任何合适的一种或多种烃前体都可以是候选物,但在一些实施例中,前体包括在25℃下具有1,000Pa或更高的蒸气压的不饱和或环状烃。在一些实施例中,前体是选自以下的至少一种:C2-C8炔烃(CnH2n-2)、C2-C8烯烃(CnH2n)、C2-C8二烯(CnHn+2)、C3-C8环烯烃、C3-C8轮烯(CnHn)、C3-C8环烷烃和前述的取代烃。在一些实施例中,前体为乙烯、乙炔、丙烯、丁二烯、戊烯、环戊烯、苯、苯乙烯、甲苯、环己烯和/或环己烷。
在一些实施例中,作为用于沉积可流动膜的间隙填充技术,可使用美国专利申请号16/026,711中公开的方法,其在其中不需要氮、氧或氢等离子体的条件下,通过使用烃前体的等离子体辅助沉积来提供完全的间隙填充,而基本上不形成空隙,所述美国专利申请的公开内容以引用的方式整体并入本文。
通过改变沉积条件或工艺参数,可形成不可流动的膜。例如,此类参数包括但不限于前体的分压、沉积温度、沉积压力等。例如,通过增加沉积温度、降低沉积压力和/或降低前体比率(前体流量与载气/稀释气体流量的比率),膜的流动性变低。在一些实施例中,工艺(i)(沉积工艺)通过等离子体增强的原子层沉积(PEALD)或其它循环的等离子体辅助沉积(例如,循环PECVD)来进行。作为等离子体,可以使用电容耦合等离子体、电感耦合等离子体、远程等离子体、由RF功率生成的等离子体、由微波生成的等离子体等。
在一些实施例中,使用直接或远程氧或氢等离子体进行步骤(ii)中的等离子体灰化。在一些实施例中,直接或远程氧或氢等离子体为选自以下的气体的直接或远程等离子体:完全为H2;Ar和H2的混合物(Ar/H2流量比为0.005至0.995,通常0.05至0.75);He和H2的混合物(He/H2流量比为0.005至0.995,通常0.05至0.75);N2和H2的混合物(N2/H2流量比为0.005至0.995,通常0.05至0.75);完全为O2;O2和Ar的混合物(O2/Ar流量比为0.005至0.995,通常0.05至0.75);O2和He的混合物(O2/He流量比为0.005至0.995,通常0.05至0.75);O2和N2的混合物(O2/N2流量比为0.005至0.995,通常0.05至0.75)。
在一些实施例中,凹部的纵横比在10至150(通常15至100)的范围内,凹部的深度大于200nm,其中凹部在步骤(i)中以无底方式用膜填充并且填充的膜的顶部部分封闭凹部的顶部开口。在一些实施例中,在步骤(ii)中进行等离子体灰化以打开凹部的封闭的顶部部分并主要或基本上仅留下填充膜的侧壁部分。
在一些实施例中,衬底具有纵横比为2至30(通常3至20)的多个凹部,其中所述凹部在步骤(i)中以自下而上的方式用膜填充,其中由于负载效应,表面拓扑存在变化。在一些实施例中,步骤(i)继续直到在所述多个凹部上方发生膜的平坦化,然后在步骤(ii)中进行等离子体灰化以使填充在所述多个凹部中的膜的表面拓扑均匀,并主要或基本上仅留下填充膜的底部部分。
将结合附图来说明实施例。然而,本发明不旨在局限于这些附图。
图2为示意根据本发明的实施例进行自下而上的沉积((a)(b)(c))和无底沉积((a)(d)(e))的沟槽的示意性横截面图的图。首先,在图2的(a)中,提供具有沟槽的衬底,其中对于自下而上的沉积,衬底21具有沟槽20,该沟槽具有足够宽以允许可流动膜流入沟槽中的宽度,并具有足够小以允许可流动膜到达沟槽20的底部的深度,而对于无底沉积,衬底31具有沟槽30,该沟槽具有足够宽以允许可流动膜流入沟槽中但足够窄以在膜到达沟槽30的底部之前由膜堵塞沟槽30的顶部开口的宽度,并具有足够大以不允许可流动膜到达沟槽30的底部的深度。举例来说,合适的沟槽尺寸在本公开中描述并可根据例如膜的流动性来选择。应指出,图2被过度简化并且没有按比例缩放。
接下来,在沉积过程中,除了沉积循环数、灰化的持续时间等外,(b)中的自下而上的沉积和(d)中的无底沉积二者可使用相同的沉积条件,沉积循环数、灰化的持续时间等要根据沟槽的大小、膜的目标沉积厚度、目标灰化量、膜的目标最终拓扑等来改变。在(b)中,可流动膜以自下而上的方式填充沟槽20并在完全填充沟槽20后连续地沉积在衬底21上,直到膜22的顶表面平坦化。平坦化可由于膜的流动性而实现。在(d)中,可流动膜沉积在衬底31的顶部上并流入沟槽30中,从而以无底的方式沿沟槽30的侧壁向下移动,同时由可流动膜32堵塞沟槽30的顶部开口。由于可流动膜沿纵横比为例如约10至100的沟槽30的侧壁向下流动,故侧壁上的膜沿侧壁基本上保形,其可用作间隔物。应指出,可通过对每个沉积调整膜的流动性来对具有相同尺寸的沟槽进行自下而上的沉积和无底沉积。例如,可使用美国专利申请号16/026,711中公开的调整流动性的方法。
接下来,在灰化过程中,从暴露于等离子体的顶表面去除(灰化)构成膜的无定形碳至适于仅底部拓扑或仅侧壁拓扑的深度。在(c)中,通过去除沉积在衬底21的顶表面上的膜22的部分和以自下而上的方式填充在沟槽20中的膜22的上部部分,可获得具有仅底部拓扑的膜23,其是均匀的并具有基本上均匀的深度。在(e)中,通过去除沉积在衬底31的顶表面上的膜32的部分和以无底方式封闭沟槽30的上部开口的膜32的上部部分,可获得具有仅侧壁拓扑的膜33,其是均匀的并具有基本上均匀的厚度。
在一些实施例中,优选地,沉积过程使用ALD样工作程序(例如,进料/吹扫/等离子体撞击/吹扫),其中在进料之后的吹扫被自愿地严重缩短以在等离子体撞击期间保留前体的高分压,如美国专利申请号16/026,711中所公开。这明显区别于ALD化学或机制。上述过程可基于脉冲等离子体CVD,它也赋予所得膜良好填充能力,但如稍后所论述,ALD样工作程序可更有益。
在一些实施例中,不同于常规的ALD,沉积膜的流动性的关键方面包括:
1)用于使聚合/链生长进展的整个RF开启时段期间足够高的分压;
2)足以激活反应(由RF开启时段和RF功率限定)的能量,不过长的RF开启时段;和
3)设定成高于可流动相的熔点但低于沉积材料的沸点的聚合/链生长温度和压力。
在一些实施例中,如下调节工艺参数范围以调整膜的流动性:
表1(数值为近似值)
低←粘度→高 | |
前体分压(Pa) | >50(优选地,>200) |
晶片温度(℃) | -10至200(优选地,50至150) |
总压力(Pa) | 300至101325(优选地,>500) |
就压力而言,高压对于流动性是优选的,因为重力和表面张力是膜在底部处流动的驱动力。就温度而言,低温对于流动性是优选的(这不太直观得多),尽管高温有利于聚合物链生长速率。
图12为示意根据本发明的一个实施例的成膜工艺序列的图,其中灰色的单元格表示开启状态,而白色的单元格表示关闭状态,并且每一列的宽度不代表每个工艺的持续时间。自下而上的沉积和无底沉积二者均可采用此简化工艺序列,并且在一些实施例中,除了沉积循环数、灰化的持续时间等外,自下而上的沉积和无底沉积二者可使用相同的沉积条件,沉积循环数、灰化的持续时间等要根据沟槽的大小、膜的目标沉积厚度、目标灰化量、膜的目标最终拓扑等来改变。
此工艺序列包括沉积工艺(“进料”→“吹扫”→“RF脉冲-1”(等离子体聚合)→“吹扫”),以及等离子体灰化工艺(“稳定化”→“RF脉冲-2”(等离子体灰化)→“吹扫”)。等离子体聚合工艺包括使用无Si和金属、含有C的前体和等离子体生成气体通过PEALD样沉积在具有沟槽的衬底上沉积无定形碳聚合物膜,所述等离子体生成气体通过在两个电极之间施加RF功率(RF)而生成等离子体,衬底平行于两个电极放置在两个电极之间,其中在PEALD样沉积的每个亚层沉积循环中施加RF功率,其中所述等离子体生成气体和运载气体连续地流动并还在“进料”之后的“吹扫”期间和“RF脉冲-1”之后的“吹扫”期间充当吹扫气体。
在一些实施例中,进料时间在0.3至10秒(通常0.6至2秒)的范围内,进料之后的吹扫时间在0至0.5秒(通常0至0.3秒)的范围内,RF时间在0.5至2秒(通常0.8至1.5秒)的范围内,RF之后的吹扫时间在0至0.5秒(通常0至0.1秒)的范围内,运载气体流量在0至0.8slm(通常0.1至0.3slm)的范围内,等离子体生成气体流量在0至0.5slm(通常0.1至0.3slm)的范围内,对于300-mm晶片RF功率在50至400W(通常75至200W)的范围内(对于不同尺寸的晶片,上述瓦特数按每个晶片的单位面积(cm2)的W应用)。
当例如挥发性烃前体通过等离子体聚合并沉积在衬底的表面上时,将暂时获得膜的流动性,其中气态单体(前体)通过等离子体气体放电所提供的能量活化或片段化以引发聚合,并且当所得聚合物材料沉积在衬底的表面上时,材料显示出暂时可流动行为。当沉积步骤完成时,可流动膜不再可流动,而是凝固的,并且因此不需要单独的凝固过程。
沉积工艺为PEALD样工艺,在开始等离子体灰化工艺之前其形成亚层(通常比单层厚)的一个循环可被重复q次直至获得所需厚度的无定形碳聚合物膜,对于自下而上的沉积,取决于沟槽的大小、膜的预期用途等,其中q为5至100(优选地25至50)的整数,以在开始等离子体灰化工艺之前在衬底的顶表面上方沉积厚度为2.5nm至50nm(优选地7.5nm至25nm)的无定形碳聚合物膜;对于无底沉积,取决于沟槽的大小、膜的预期用途等,其中q为10至200(优选地40至100)的整数,以在开始等离子体灰化工艺之前在衬底的顶表面上方沉积厚度为5nm至100nm(优选地20nm至50nm)的无定形碳聚合物膜。
接下来,开始等离子体灰化工艺,其包括向反应空间进料灰化气体(H2或O2,或前述与N2、Ar和/或He的混合物)(“稳定化”),所述灰化气体被RF功率(RF)激发而生成等离子体并灰化无定形碳聚合物膜(“RF脉冲-2”),然后是吹扫(“吹扫”),其中在整个等离子体灰化工艺中灰化气体被连续进料到反应腔室。在一些实施例中,用于等离子体灰化的RF功率在50至500W(通常50至200W)的范围内,压力为100Pa至1000Pa(通常200至600Pa),持续时间为5至200秒(通常10至100秒),稳定化时间在5至60秒(通常10至30秒)的范围内,RF之后的吹扫时间在5至60秒(通常10至30秒)的范围内,灰化气体流量在0.1至10slm(通常0.5至2slm)的范围内。
在一些实施例中,在整个工艺过程中,运载气体例如以0sccm至2000sccm(优选地100sccm至500sccm)的范围连续地进料到反应空间。另外,工艺的温度可在-50℃至175℃(优选地35℃至150℃)的范围内。
沉积工艺中的等离子体生成气体和等离子体灰化工艺中的灰化气体可相同或不同,例如,两者均可为Ar和/或He。
运载气体的连续流动可使用流通系统(FPS)实现,其中运载气体管线提供有具有前体储罐(瓶)的绕道管线,并且在主管线和绕道管线之间切换,其中当仅意在向反应腔室进料运载气体时,关闭绕道管线,而当意在向反应腔室进料运载气体和前体气体二者时,关闭主管线,运载气体流经绕道管线并与前体气体一道从瓶流出。这样,运载气体可连续地流进反应腔室中并可通过在主管线与绕道管线之间切换而以脉冲形式携带前体气体。图1B示意了根据本发明的一个实施例的使用流通系统(FPS)的前体供应系统(黑色阀门指示该阀门是关闭的)。如图1B中(a)中所示,当向反应腔室进料前体时(未示出),第一运载气体如Ar(或He)流经具有阀门b和c的气体管线,并然后进入瓶(储存器)26。运载气体从瓶26流出,同时携带量对应于瓶26内部的蒸气压的前体气体,流过具有阀门f和e的气体管线,并然后与前体一起进料到反应腔室。在上文中,阀门a和d是关闭的。当向反应腔室仅进料运载气体(稀有气体)时,如图1B中(b)中所示,运载气体流经具有阀门a的气体管线,同时绕过瓶26。在上文中,阀门b、c、d、e和f是关闭的。
工艺循环可使用任何合适的装置进行,包括例如图1A中示意的装置。图1A为PEALD装置的示意图,该装置宜与编程为进行下文所述序列的控制器结合,可用于本发明的一些实施方案中。在此图中,通过在反应腔室3的内部11(反应区)中提供一对并联且彼此面对面的导电平板电极4、2,向一侧施加HRF功率(13.56MHz或27MHz)25,并将另一侧12电接地,在电极之间激发等离子体。在下平台2(下电极)中提供温度调节器,并使放置在其上的基板1的温度保持恒定于给定温度下。上电极4也用作喷淋板,并分别通过气体管线27和气体管线28及通过喷淋板4向反应腔室3中引入反应物气体和/或稀释气体(如果有的话)和前体气体。另外,在反应腔室3中,提供具有排气管线7的环形管13,通过所述排气管线排出反应腔室3的内部11中的气体。另外,设置在反应腔室3下方的转移腔室5提供有密封气体管线24以经由转移腔室5的内部16(转移区)向反应腔室3的内部11中引入密封气体,转移腔室5中提供有用于分离反应区和转移区的分离板14(该图中省略了通过其向转移腔室5中或自该转移腔室转移晶片的闸阀)。转移腔室还提供有排气管线6。在一些实施例中,在同一反应空间中进行多元素膜的沉积和表面处理,使得所有步骤都可连续地进行而不将衬底暴露于空气或其他含氧气氛中。
在一些实施例中,在图1A中所描绘的装置中,图1B中示意的切换非活性气体的流量与前体气体的流量的系统(在前面描述)可用于引入脉冲形式的前体气体而基本上不使反应腔室的压力波动。
熟练技术人员应认识,所述装置包括一个或多个编程或以其他方式配置为使得沉积和本文其他地方描述的反应器清洁工艺能够进行的控制器(未示出)。如熟练技术人员应理解,所述一个或多个控制器可与各种电源、加热系统、泵、机器人装置和反应器的气体流量控制器或阀门连通。
在一些实施例中,可使用双室反应器(用于加工彼此靠近设置的晶片的两个部分或隔室),其中反应气体和稀有气体可通过共享管线供给而前体气体通过未共享管线供给。
具有填充能力的膜可应用于各种半导体装置,包括但不限于3D交叉点存储装置中的单元隔离、自对准通孔、伪栅极(替换当前的多晶Si)、反向色调图案化、PC RAM隔离、切割硬掩模和DRAM存储节点接触(SNC)隔离。
实例
在未指定条件和/或结构的以下实例中,鉴于本公开,本领域技术人员可容易地按照常规实验提供此类条件和/或结构。熟练技术人员应认识,实例中使用的装置包括一个或多个编程或以其他方式配置为使得沉积和本文其他地方描述的反应器清洁工艺能够进行的控制器(未示出)。如熟练技术人员应理解,所述一个或多个控制器与各种电源、加热系统、泵、机器人装置和反应器的气体流量控制器或阀门连通。
参考实例1(图3)
使用图1A中所示意的设备和图1B中所示意的气体供应系统(FPS)在下表2中所示的条件下根据图12中所示的工艺序列以自下而上的方式通过PEALD样工艺在具有沟槽的Si衬底(具有300mm的直径和0.7mm的厚度)上沉积无定形碳聚合物膜,沟槽具有大约25至35nm的开口并具有大约85nm的深度(纵横比为大约2.4至3.4)。膜经沉积以完全填充沟槽并在其上进一步积聚,从而形成平坦的顶表面。重复PEALD样循环242次(p=242)。其后,根据图12中所示的工艺序列在下表2中所示的条件下使用O2和Ar的混合物或者N2和H2的混合物连续地进行灰化。
表2(数值为近似值)
图3示出了沟槽的横截面图的STEM照片,其中:(a)进行自下而上的沉积的沟槽,(b):然后进行O2/Ar灰化的沟槽,(c):或进行N2/H2灰化的沟槽。如图3中所示,确认无定形碳聚合物膜是可有效流动的并完全填充所有沟槽(无论大小差异如何)并在其上进一步积聚,从而形成平坦的顶表面,并且通过灰化工艺,无定形碳聚合物膜可被完全去除或灰化而不降低CD完整性,即,通过控制灰化时间,可去除所需的量的无定形碳聚合物膜而不降低CD完整性。
实例1
在与参考实例1中相同的条件下以自下而上的方式通过PEALD样工艺在具有沟槽的Si衬底(具有300mm的直径和0.7mm的厚度)上沉积无定形碳聚合物膜,沟槽具有大约20nm的开口并具有大约200nm的深度(纵横比为大约10),不同的是重复沉积循环210次(p=210)使得膜在衬底的顶表面上积聚至100nm的厚度。其后,以与参考实例1中相同的方式使用O2和Ar的混合物连续地进行灰化,不同的是RF时间缩短至90秒以便形成具有仅底部拓扑的膜结构,其中将膜从衬底的顶表面灰化至181nm的深度。
图9示出了进行自下而上的沉积的沟槽的横截面图的STEM照片,其中(a)表示沉积完成时的沟槽,(b)表示灰化后的沟槽。如图9中所示,确认无定形碳聚合物膜是可有效流动的并完全填充所有沟槽并在其上进一步积聚,从而形成平坦的顶表面,并且通过灰化工艺,所有沟槽中无定形碳聚合物膜可被均匀地去除或灰化而不降低CD完整性,从而形成具有均匀的仅底部拓扑的均匀膜结构。
实例2
以与实例1中相同的方式在具有沟槽的Si衬底上沉积无定形碳聚合物膜,不同的是改变灰化时间。
图10示出了进行自下而上的沉积(完全填充)的沟槽的横截面图的STEM照片,其中原始的(a)表示具有不同宽度(比例尺代表300nm)的宽沟槽和窄沟槽的混合物,原始的(b)表示中等宽度沟槽(比例尺代表60nm),原始的(c)表示宽度略有差异的宽沟槽(比例尺代表60nm),列(1)表示灰化前的完全填充沉积(210次沉积循环)的沟槽,列(2)表示灰化105秒后的沟槽,列(3)表示灰化129秒后的沟槽,列(4)表示灰化165秒后的沟槽。
图11示出了进行自下而上的沉积的沟槽的横截面图的STEM照片,其中(a)表示完全填充沉积(210次沉积循环)完成时的沟槽,(b)表示灰化240秒后的沟槽,(c)表示灰化300秒后的沟槽。
如图10和11中所示,确认无定形碳聚合物膜是可有效流动的并完全填充所有沟槽并在其上进一步积聚,从而形成平坦的顶表面,并且通过灰化工艺,所有沟槽中无定形碳聚合物膜可被均匀地去除或灰化而不降低CD完整性,从而形成具有均匀的仅底部拓扑的均匀膜结构。同样还确认,出乎意料的是,完全填充沉积和灰化的组合可均匀地实现仅底部沉积而基本上无负载效应。
参考实例2
在与参考实例1中相同的条件下以无底方式通过PEALD样工艺在具有沟槽的Si衬底(具有300mm的直径和0.7mm的厚度)上沉积无定形碳聚合物膜,沟槽具有大约150nm的开口并具有大约2500nm的深度(纵横比为大约17),不同的是重复沉积循环350次(p=350)使得膜在衬底的顶表面上积聚至160nm的厚度。
已通过进行无底沉积的沟槽的横截面图的STEM照片确认了无底沉积,包括(a)一系列膜沉积沟槽的视图,(b)沟槽中之一的顶部部分的放大视图,(c)该沟槽的底部部分的放大视图,和(d)沟槽的侧壁的放大视图。已确认,尽管沟槽未被完全用膜填充,如在(a)中所观察到,但无定形碳聚合物膜是可有效流动的,其中尽管沟槽的顶部部分被膜所封闭(顶部被过填充),如在(b)中所观察到,但膜会向下流动并沿着沟槽的侧壁向着沟槽的底部延伸,如在(d)中所观察到,而不到达沟槽的底部,如在(c)中所观察到,从而沿侧壁形成基本上保形(沿侧壁具有基本上均匀的厚度)并均匀的膜结构。
参考实例3
在与参考实例1中相同的条件下以无底方式通过PEALD样工艺在具有沟槽的Si衬底(具有300mm的直径和0.7mm的厚度)上沉积无定形碳聚合物膜,沟槽具有大约140至160nm的开口并具有大约2500nm的深度(纵横比为大约16至18),不同的是重复沉积循环300次(p=300)使得膜在衬底的顶表面上积聚至116nm的厚度。
图4示出了进行无底沉积(300次循环)而不灰化的沟槽的横截面图的STEM照片的示意图。如图4中所示,确认尽管沟槽未被完全用膜填充,但无定形碳聚合物膜是可有效流动的,其中尽管沟槽的顶部部分刚刚或勉强被膜所封闭(顶部被过填充)并且尽管膜积聚在衬底的顶表面上,但膜会向下流动并沿着沟槽的侧壁向着沟槽的底部延伸并略微到达沟槽的底部,从而沿侧壁形成基本上保形(沿侧壁具有基本上均匀的厚度)并均匀的膜结构。如果将干法蚀刻条件设置为相对于下层具有高的碳膜选择性(例如,>100),则在底部处少量的膜沉积不会干扰形成超深孔的进一步蚀刻,并因此,该沉积仍被称为无底沉积。此外,通过调节膜的流动性(略微降低流动性),膜沿侧壁的流动可在到达底部之前停止。
实例3
在与参考实例3中相同的条件下以无底方式在Si衬底上沉积无定形碳聚合物膜。其后,使用O2和Ar的混合物以与参考实例1中相同的方式连续地进行灰化,不同的是RF时间缩短至90秒以使积聚在衬底的顶表面上的膜的一部分变薄并去除沟槽中膜的顶部封闭部分(过填充部分)以打开沟槽,从而在沟槽中形成间隔物样结构。
图5示出了进行无底沉积(300次循环)然后灰化(90秒)的沟槽的横截面图的STEM照片的示意图。如图5中所示,确认通过灰化,沟槽的过填充顶部部分被有效地去除以便打开沟槽的顶部而不降低CD完整性,从而沿侧壁形成基本上保形(沿侧壁具有基本上均匀的厚度)并均匀的膜结构。
参考实例4
在与参考实例3中相同的条件下以无底方式在Si衬底上沉积无定形碳聚合物膜,不同的是重复沉积循环350次(p=350)使得膜在衬底的顶表面上积聚至160nm的厚度并完全封闭沟槽的顶部开口(沟槽上方过填充部分的厚度为145nm)。
图6示出了进行无底沉积(350次循环)而不灰化的沟槽的横截面图的STEM照片的示意图。如图6中所示,确认尽管沟槽未被完全用膜填充,但无定形碳聚合物膜是可有效流动的,其中尽管沟槽的顶部部分被膜所封闭并且尽管膜积聚在衬底的顶表面上,但膜以与参考实例3中相似的方式向下流动并沿着沟槽的侧壁向着沟槽的底部延伸。
实例4
在与参考实例4中相同的条件下以无底方式在Si衬底上沉积无定形碳聚合物膜。其后,使用O2和Ar的混合物以与参考实例1中相同的方式连续地进行灰化,不同的是RF时间缩短至90秒以使积聚在衬底的顶表面上的膜的一部分变薄并去除沟槽中膜的顶部封闭部分(过填充部分)以打开沟槽,从而在沟槽中形成间隔物样结构(沟槽上方过填充部分的厚度为95nm)。
图7示出了进行无底沉积(350次循环)然后灰化(90秒)的沟槽的横截面图的STEM照片的示意图。如图7中所示,确认通过灰化,沟槽的过填充顶部部分被有效地去除以便打开每个沟槽的顶部而不降低CD完整性,从而沿侧壁形成基本上保形(沿侧壁具有基本上均匀的厚度)并均匀的膜结构。
本领域技术人员应理解,可作许多和各种修改而不偏离本发明的精神。因此,应清楚地理解,本发明的形式仅是示意性的,而非意在限制本发明的范围。
Claims (10)
1.一种在衬底的图案化凹部上形成拓扑受控的层的方法,所述方法包括:
(i)通过脉冲等离子体辅助沉积在所述衬底的所述图案化凹部上沉积具有填充能力的无Si含C膜以以自下而上的方式或无底方式填充所述凹部;和
(ii)对所述凹部中填充的自下而上或无底的膜进行等离子体灰化以以主要或基本上仅留下填充膜的底部部分或者主要或基本上仅留下填充膜的侧壁部分的方式去除所述填充膜的顶部部分。
2.根据权利要求1所述的方法,其中步骤(ii)中的所述等离子体灰化使用直接或远程氧或氢等离子体进行。
3.根据权利要求2所述的方法,其中所述直接或远程氧或氢等离子体为选自以下的气体的直接或远程等离子体:完全为H2;Ar和H2的混合物;N2和H2的混合物;He和H2的混合物;完全为O2;O2和Ar的混合物;O2和He的混合物;O2和N2的混合物。
4.根据权利要求1所述的方法,其中在步骤(i)中,使用烃前体来沉积所述无Si含C膜。
5.根据权利要求1所述的方法,其中步骤(i)包括:(ia)向放置所述衬底的反应空间供应前体,和(ib)将所述衬底的所述图案化凹部暴露于等离子体以在所述图案化凹部中沉积所述无Si含C膜,其中步骤(ib)以脉冲所述等离子体的方式间歇地进行,并且步骤(ia)作为步骤(ib)的先决步骤连续或间歇地进行,与步骤(ib)无交叠。
6.根据权利要求1所述的方法,其中所述无Si含C膜基本上由烃构成。
7.根据权利要求1所述的方法,其中所述凹部的纵横比在10至100的范围内,并且所述凹部的深度大于200nm,其中所述凹部在步骤(i)中以无底方式用所述膜填充并且所述填充膜的顶部部分封闭所述凹部的顶部开口。
8.根据权利要求6所述的方法,其中在步骤(ii)中进行等离子体灰化以打开所述凹部的封闭的顶部部分并主要或基本上仅留下所述填充膜的侧壁部分。
9.根据权利要求1所述的方法,其中所述衬底具有纵横比为2至30的多个凹部,其中所述凹部在步骤(i)中以自下而上的方式用所述膜填充,其中由于负载效应,表面拓扑存在变化。
10.根据权利要求8所述的方法,其中步骤(i)继续直到在所述多个凹部上方发生所述膜的平坦化,然后在步骤(ii)中进行等离子体灰化以使填充在所述多个凹部中的膜的表面拓扑均匀,并主要或基本上仅留下所述填充膜的底部部分。
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US11282698B2 (en) | 2022-03-22 |
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