KR102657269B1 - 주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하는 방법 - Google Patents

주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하는 방법 Download PDF

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KR102657269B1
KR102657269B1 KR1020207023070A KR20207023070A KR102657269B1 KR 102657269 B1 KR102657269 B1 KR 102657269B1 KR 1020207023070 A KR1020207023070 A KR 1020207023070A KR 20207023070 A KR20207023070 A KR 20207023070A KR 102657269 B1 KR102657269 B1 KR 102657269B1
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ruthenium
metal
precursor
substrate
organic
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KR1020207023070A
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KR20200119806A (ko
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마티아스 민야우
욜린 덴도번
크리스토퍼 데타베르니르
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에이에스엠 아이피 홀딩 비.브이.
유니베어지테트 헨트
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    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
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Abstract

주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하는 방법이 개시된다. 본 방법은, 백금, 알루미늄, 티타늄, 비스무스, 아연, 및 이들의 조합으로 이루어진 군으로부터 선택된 금속을 포함한 금속유기 전구체를 포함하는 제1 기상 반응물과 기판을 접촉시키는 단계를 포함할 수 있다. 본 방법은 또한, 사산화루테늄을 포함한 제2 기상 반응물과 기판을 접촉시키는 단계를 포함할 수 있되, 루테늄-함유 막은 루테늄-백금 합금, 또는 삼원 루테늄 산화물 중 적어도 하나를 포함한다. 본 개시의 방법에 의해 증착된 루테늄-함유 막을 포함한 반도체 소자 구조도 개시된다.

Description

주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하는 방법
본 발명은 일반적으로 주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하는 방법, 특히 금속유기 전구체와 사산화루테늄을 이용해 루테늄-함유 막을 증착하는 방법에 관한 것이다.
일반적으로 첨단 기술 분기점에서의 반도체 소자 제조 공정은, 예를 들어 루테늄-함유 막과 같은 금속-함유 막을 형성하기 위한 최신 증착 방법을 필요로 한다.
금속-함유 막의 증착을 위한 공통적인 요건은, 증착 공정이 매우 등각성이라는 것이다. 예를 들어, 높은 종횡비 특징을 포함하는 3차원 구조 위에 금속-함유 막을 균일하게 증착하기 위해 등각성 증착을 자주 요구한다. 금속-함유 막의 증착을 위한 또 다른 공통 요건은, 증착 공정이 대형 기판 영역 위에 걸쳐 초박막을 연속적으로 증착할 수 있어야 한다는 것이다. 금속-함유 막이 전기 전도성인 구체적인 경우에, 증착 공정은 낮은 저항의 전도성 막을 생성하도록 최적화될 필요가 있을 수 있다.
예를 들어 원자층 증착(ALD) 및 주기적 화학 기상 증착(CCVD)과 같은 주기적 증착 공정은, 반응 챔버 내로 하나 이상의 전구체(반응물)를 순차적으로 도입하고, 상기 전구체는 순차적이고 자기 제한적인 방식으로 한 번에 하나씩 기판의 표면 상에서 반응한다. 원자 수준의 두께 제어와 우수한 등각성을 갖는 금속-함유 막을 제조하는 주기적 증착 공정이 시연되어 왔다.
주기적 증착 방법은 금속 합금의 증착에 사용될 수 있다. 예를 들어, 제1 금속을 포함한 제1 전구체 및 제2 금속을 포함한 제2 전구체를 이용하는 원자층 증착 공정에 의해 금속 합금을 증착할 수 있다. 따라서, 금속 합금을 증착하는 방법, 및 하나 이상의 금속 합금을 포함한 반도체 소자 구조가 요구된다.
금속 합금 이외에, 주기적 증착 방법은 또한 금속 산화물의 증착에 사용될 수 있다. 예를 들어, 금속을 포함한 제1 전구체, 및 산소 성분을 포함한 제2 전구체를 이용하는 원자층 증착 공정에 의해 금속 산화물을 증착할 수 있다. 삼원 금속 산화물은 차세대 소자에 대한 특정한 가치를 가질 수 있다. 그러나, 삼원 금속 산화물을 형성하기 위한 일반적인 증착 공정은, 예를 들어 제1 금속 전구체, 제2 금속 전구체, 및 산소 성분을 함유한 전구체와 같은 세 개의 별도 전구체를 필요로 할 수 있다. 따라서, 증착 금속 산화물, 및 특히 삼원 금속 산화물을 위한 개선된 방법이 바람직하다.
본 발명의 내용은 선정된 개념을 단순화된 형태로 소개하기 위해 제공된다. 이들 개념은 하기의 본 발명의 예시적 구현예의 상세한 설명에 더 상세하게 기재되어 있다. 본 발명의 내용은 청구된 요지의 주된 특징 또는 필수적인 특징을 구분하려는 의도가 아니며 청구된 요지의 범주를 제한하기 위해 사용하려는 의도 또한 아니다.
일부 구현예에서, 주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하는 방법이 제공된다. 상기 방법은, 백금, 팔라듐, 알루미늄, 티타늄, 비스무스, 아연 및 이들의 조합으로 이루어진 군으로부터 선택된 금속을 포함하는 금속유기 전구체를 포함한 제1 기상 반응물과 상기 기판을 접촉시키는 단계; 및 사산화루테늄을 포함한 제2 기상 반응물과 상기 기판을 접촉시키는 단계를 포함하되, 상기 루테늄-함유 막은 루테늄-백금 합금, 루테늄-팔라듐 합금, 또는 삼원 루테늄 산화물 중 적어도 하나를 포함한다.
선행 기술에 비해 달성되는 장점 및 본 발명을 요약하기 위해, 본 발명의 특정 목적 및 장점이 앞서 본원에 기술되었다. 물론, 모든 목적 및 장점들이 본 발명의 임의의 특별한 구현예에 따라 반드시 달성되는 것이 아니라는 것을 이해하여야 한다. 따라서, 예들 들어 당업자는, 본 발명이, 본원에 교시 또는 제안될 수 있는 다른 목적들 또는 장점들을 반드시 달성하지 않고서, 본원에 교시되거나 제시된 바와 같은 하나의 장점 또는 여러 장점들을 달성하거나 최적화하는 방식으로 구현되거나 수행될 수 있다는 것을 인식할 것이다.
이들 구현예 모두는 본원에 개시된 본 발명의 범주 내에 있는 것으로 의도된다. 본 발명은 개시된 임의의 특정 구현예(들)에 한정되지 않으며, 이들 및 다른 구현예들은 첨부된 도면들을 참조하는 특정 구현예들의 다음의 상세한 설명으로부터 당업자에게 용이하게 분명할 것이다.
본 명세서는 본 발명의 구현예로 간주되는 것을 특별히 지적하고 명백하게 주장하는 청구범위로 결론을 내지만, 본 개시의 구현예들의 장점들은 첨부한 도면들과 관련하여 읽을 때 본 개시의 구현예들의 특정 예의 설명으로부터 더욱 쉽게 확인될 수 있고, 도면들 중:
도 1은 본 개시의 구현예에 따른 예시적인 주기적 증착 방법의 공정 흐름를 나타낸다.
도 2는 본 개시의 구현예에 따라 증착된 루테늄-함유 막을 포함하는 반도체 소자 구조의 단면도를 개략적으로 나타낸다.
도 3은 본 개시의 방법을 수행하도록 구성된 반응 시스템의 개략도를 나타낸다.
특정 구현예 및 실시예가 아래에 개시되었지만, 당업자는 본 발명이 구체적으로 개시된 구현예 및/또는 본 발명의 용도 및 이들의 명백한 변형물 및 균등물을 넘어 확장된다는 것을 이해할 것이다. 따라서, 개시된 발명의 범주는 후술되는 구체적인 개시된 구현예에 의해 제한되지 않도록 의도된다.
본원에 제시된 예시는 임의의 특정한 물질, 구조, 또는 소자의 실제 뷰를 의도하려 하는 것은 아니며, 단지 본 발명의 구현예를 설명하기 위해 사용되는 이상화된 표현이다.
본원에서 사용되는 바와 같이, 용어 "주기적 증착"은 반응 챔버 내로 전구체(반응물)를 순차적으로 도입시켜 기판 위에 막을 증착하는 것을 지칭할 수 있으며 원자층 증착 및 주기적 화학 기상 증착과 같은 증착 기술을 포함한다.
본원에서 사용되는 바와 같이, 용어 "주기적 화학 기상 증착"은 원하는 증착을 생성시키기 위해 기판 상에서 반응 및/또는 분해되는 둘 이상의 휘발성 전구체에 기판이 순차적으로 노출되는 임의의 공정을 지칭할 수 있다.
본원에서 사용되는 바와 같이, 용어 "기판"은, 사용될 수 있는, 또는 그 위에 소자, 회로, 또는 막이 형성될 수 있는, 임의의 하부 재료 또는 재료들을 지칭할 수 있다. 기판은 웨이퍼, 글라스, 폴리머, 플라스틱, 고체 물질, 섬유 및 분말을 포함할 수 있지만, 이에 제한되지 않는다.
본원에서 사용되는 바와 같이, 용어 "원자층 증착"(ALD)은 기상 증착 공정을 지칭할 수 있고, 여기서 증착 사이클은, 바람직하게는 복수의 연속 증착 사이클은 공정 챔버에서 수행된다. 일반적으로, 각각의 사이클 중에 전구체는 증착 표면(예, 기판 표면, 또는 이전 ALD 사이클로부터의 물질과 같은 이전에 증착된 하부 표면)에 화학 흡착되고, 추가적인 전구체와 쉽게 반응하지 않는(즉, 자기 제한적 반응) 단층 또는 서브 단층을 형성한다. 그 후 필요한 경우, 증착 표면 상에서 화학 흡착된 전구체를 원하는 재료로 전환시키는 용도로, 반응물(예를 들어, 다른 전구체 또는 반응 가스)이 후속해서 공정 챔버에 유입될 수 있다. 일반적으로, 이러한 반응물은 전구체와 더 반응할 수 있다. 각각의 사이클 중에 공정 챔버로부터 과잉의 전구체를 제거하고/하거나, 화학 흡착된 전구체의 변환 후 공정 챔버로부터 과잉의 반응물 및/또는 반응 부산물을 제거하기 위해 퍼지 단계들이 더 활용될 수도 있다. 추가로, 본원에서 사용된 용어 "원자층 증착"은 전구체 조성물(들), 반응 가스, 및 퍼지(예, 불활성 캐리어) 가스의 교번 펄스로 수행되는 경우, "화학 기상 원자층 증착", "원자층 에피택시" (ALE), 분자 빔 에피택시(MBE), 가스 공급원 MBE, 또는 유기금속 MBE, 및 화학적 빔 에피택시와 같은 관련 용어들에 의해 지정된 공정을 포함하는 것을 또한 의미한다.
본원에서 사용되는 바와 같이, 용어 "막" 및 "박막"은 본원에 개시된 방법에 의해 증착된 임의의 연속적인 또는 비연속적인 구조 및 재료를 지칭할 수 있다. 예를 들어, "막" 및 "박막"은 2D 재료, 나노막대, 나노튜브, 또는 나노입자 또는 심지어는 부분 또는 전체 분자층 또는 부분 또는 전체 원자층 또는 원자 및/또는 분자 클러스터를 포함할 수 있다. "막" 및 "박막"은 핀홀을 포함하는 재료 또는 층을 포함할 수 있지만, 여전히 적어도 부분적으로 연속적일 수 있다.
본원에서 사용되는 바와 같이, 용어 "금속유기" 또는 "유기금속"은 상호 교환해서 사용되고, 금속 종을 함유하는 유기 화합물을 지칭할 수 있다. 유기금속 화합물은 금속-탄소의 직접 결합을 갖는 금속유기 화합물의 하위 클래스로 간주될 수 있다.
다수의 예시적인 물질은 본 개시의 구현예를 통해 주어지고, 예시적인 물질 각각에 주어진 화학식을 제한적인 것으로 이해해서는 안되고, 주어진 비제한적 예시적인 물질이 주어진 예시적 화학량론에 의해 한정되어서는 아니되는 점을 주목해야 한다.
본 개시는 루테늄-함유 막 증착에 활용될 수 있는 방법, 특히 루테늄-백금 합금, 루테늄-팔라듐 합금, 또는 삼원 루테늄 산화물 막을 증착하기 위한 증착 방법을 포함한다.
루테늄(Ru)은, DRAM 커패시터 및 MOSFET 용으로 잠재적인 고-일함수 전극 물질이다. 또한, 루테늄은 연료전지 전극, 촉매 및 집적회로 배선을 위한 배리어층 상의 구리(Cu)의 전착을 위한 시드층으로서 유용한 용도를 가질 수 있다. 그러나, 루테늄 전구체는 매우 고가이기 때문에 원소 루테늄의 증착은 비용적으로 효율적이지 못하다. 따라서, 본 개시의 방법은, 원하는 소자의 용도에 기초하여 루테늄-백금 합금의 조성을 맞출 수 있는 루테늄-금속 합금을 증착함으로써, 보다 적은 루테늄 전구체를 이용하면서 조정된 특성을 갖는 루테늄-백금 합금을 증착시키는 방법을 포함한다.
루테늄-백금 금속 합금 이외에도, 본 개시의 구현예는 삼원 루테늄 산화물을 증착하기 위한 방법을 또한 제공할 수도 있다. 비제한적인 예시적 구현예로서, 본 개시의 방법은, 연료 전지 응용을 가질 수 있는 루테늄 티타늄 산화물(RuxTiyOz) 및 비스무스 루테늄 산화물(BixRuyOz)의 증착을 위해 사용될 수 있다.
따라서 본 개시의 구현예는, 주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하기 위한 방법을 포함할 수 있다. 상기 방법은, 금속유기 전구체를 포함한 제1 기상 반응물과 상기 기판을 접촉시키는 단계; 및 사산화루테늄을 포함한 제2 기상 반응물과 상기 기판을 접촉시키는 단계를 포함할 수 있다.
주기적 증착 공정의 비제한적이고 예시적인 구현예는 원자층 증착(ALD)을 포함할 수 있고, ALD는 일반적으로 자기 제한적 반응에 기반하며, 이에 의해 교대 순차적인 반응물 펄스가 증착 사이클당 약 하나의 원자(또는 분자) 단층을 증착하기 위해 사용된다. 증착 조건 및 전구체는 통상적으로 자가 포화 반응을 제공하도록 선택되어, 하나의 반응물의 흡착된 층이 동일한 반응물의 기상 반응물과 비반응성인 표면 종결부를 남긴다. 후속적으로 기판은 이전의 종결부와 반응하는 상이한 반응물과 접촉되어, 연속된 증착을 가능하게 한다. 따라서, 교번 펄스의 각각의 사이클은 통상적으로 원하는 재료를 약 단일층 이하로 남긴다. 그러나, 전술된 바와 같이, 당업자는 하나 이상의 ALD 사이클에서, 예를 들면 공정의 교번 특성에도 불구하고 몇몇 기상 반응이 발생하는 경우, 단일층보다 많은 재료가 증착될 수 있음을 인식할 것이다.
루테늄-함유 막을 증착하기 위한 ALD 유형 공정에서, 하나의 증착 사이클은, 상기 기판을 제1 반응물에 노출시키는 단계, 임의의 미반응된 제1 반응물 및 반응 부산물을 반응 공간으로부터 제거하는 단계, 및 상기 기판을 제2 반응물에 노출시키고 이어서 제2 제거 단계를 포함할 수 있다. 상기 제1 반응물은 금속유기 전구체("금속유기 전구체")를 포함할 수 있고 상기 제2 반응물은 사산화루테늄("루테늄 전구체")을 포함할 수 있다.
반응물 사이의 기상 반응을 방지하고 자기 포화 표면 반응을 가능하게 하도록, 전구체는 아르곤(Ar) 또는 질소(N2)와 같은 불활성 가스에 의해 분리될 수 있다. 그러나, 일부 구현예에서 기판을 제1 기상 반응물 및 제2 기상 반응물과 별도로 접촉하도록 이동시킬 수 있다. 반응은 자기 포화되기 때문에, 기판의 엄격한 온도 제어 및 전구체의 정확한 투여량 제어는 대개 요구되지 않는다. 그러나, 기판 온도는 입사 가스 종이 단층으로 응축되지 않거나 표면에서 분해되지 않도록 하는 것이 바람직하다. 잉여 화학 물질 및 반응 부산물이 존재하는 경우, 기판이 다음 반응 화학 물질과 접촉하기 전에 이들은, 예를 들어 반응 공간을 퍼지하거나 기판을 이동함으로써 기판 표면으로부터 제거된다. 원하지 않는 가스 분자들은 불활성 퍼지 가스의 도움으로 반응 공간으로부터 효과적으로 방출될 수 있다. 진공 펌프는 퍼지를 돕는 데 사용될 수 있다.
루테늄-함유 막을 증착하기 위해 사용될 수 있는 반응기가 증착을 위해 사용될 수 있다. 이러한 반응기는 전구체를 제공하기 위한 적절한 장비 및 수단을 구비한 CVD 반응기뿐만 아니라 ALD 반응기를 포함한다. 일부 구현예에 따라, 샤워헤드 반응기가 사용될 수 있다. 일부 구현예에 따라, 크로스 플로우, 배치, 미니배치 또는 공간 ALD 반응기가 사용될 수 있다.
사용될 수 있는 적합한 반응기의 예는 상업적으로 이용 가능한 단일 기판(또는 단일 웨이퍼) 증착 설비, 예컨대 미국 애리조나주 피닉스 소재의 ASM America, Inc. 및 네덜란드 알메레 소재의 ASM Europe B.V로부터 이용 가능한 Pulsar® 반응기(예, Pulsar® 2000 및 Pulsar® 3000 및 Pulsar® XP ALD), 및 EmerALD® XP 및 EmerALD® 반응기를 포함한다. 다른 상업적으로 이용 가능한 반응기는 Eagle® XP 및 XP8의 상표명을 가진 ASM Japan K.K.(일본, 동경)사의 제품들을 포함한다. 일부 구현예에서 반응기는, 기판이 공정 중에 이동 또는 회전하는 공간 ALD 반응기이다.
본 개시의 일부 구현예에서, 배치식 반응기가 사용될 수 있다. 적합한 배치식 반응기는 A400 및 A412 PLUS라는 상표명으로 ASM Europe B.V(네덜란드, 알메르)사로부터 상업적으로 이용 가능한 Advance® 400 시리즈 반응기를 포함하나 이에 제한되지 않는다. 일부 구현예에서, 공정 처리 동안 보트가 회전하는 A412와 같은 수직형 배치식 반응기가 활용된다. 이처럼, 일부 구현예에서, 웨이퍼는 공정 도중에 회전한다. 다른 구현예에서, 배치식 반응기는 10매 이하의 웨이퍼, 8매 이하의 웨이퍼, 6매 이하의 웨이퍼, 4매 이하의 웨이퍼 또는 2매 이하의 웨이퍼를 수용하도록 구성된 미니배치식 반응기를 포함한다. 배치식 반응기가 사용되는 일부 구현예에서, 웨이퍼 대 웨이퍼의 불균일도는 3%(1시그마) 미만, 2% 미만, 1% 미만, 또는 심지어 0.5% 미만이다.
본원에서 설명되는 증착 공정은 클러스터 툴에 연결된 반응 챔버 또는 반응기에서 선택적으로 수행될 수 있다. 클러스터 툴에서, 각각의 반응 공간은 하나의 유형의 공정에 전용되기 때문에, 각 모듈 내의 반응 공간의 온도는 일정하게 유지될 수 있으며, 이는 각 공정 실행 전에 기판이 공정 온도로 가열되는 반응기에 비해 처리량을 향상시킨다. 추가적으로 클러스터 툴에서는, 기판들 사이의 원하는 공정 압력 레벨까지 반응 공간을 펌핑하는 시간이 줄어들 수 있다. 본 개시의 일부 구현예에서, 증착 공정은 다수의 반응 챔버를 포함하는 클러스터 툴에서 수행될 수 있으며, 각각의 개별 반응 챔버는 기판을 개별적인 전구체 가스에 노출시키는 데 사용될 수 있으며, 기판은 다수의 전구체 가스에 노출시키기 위해 상이한 반응 챔버 사이에서 이송될 수 있으며, 기판의 이송은 기판의 산화/오염을 방지하기 위해 제어된 분위기 하에서 수행된다. 본 발명의 일부 구현예에서, 증착 공정은 다수의 반응 챔버를 포함하는 클러스터 툴에서 수행될 수 있으며, 각각의 개별 반응 챔버는 기판을 다른 온도로 가열하도록 구성될 수 있다.
독립형 반응기에는 로드록이 장착될 수 있다. 이러한 경우, 각각의 공정 실행 사이에 반응 공간을 냉각할 필요가 없다. 일부 구현예에서, 금속 함유막 증착을 위한 증착 공정은, 복수의 증착 사이클, 예를 들어 ALD 사이클 또는 주기적 CVD 사이클을 포함할 수 있다.
일부 구현예에서, 주기적 증착 공정은 기판 상에 루테늄-함유 막을 증착하기 위해 사용되고, 이러한 주기적 증착 공정은 ALD형 공정일 수 있다. 일부 구현예에서, 주기적 증착은 하이브리드 ALD/CVD 또는 주기적 CVD 공정일 수 있다. 예를 들면, 일부 구현예에서, ALD 공정의 성장 속도는 CVD 공정에 비해 낮을 수 있다. 성장 속도를 증가시키는 하나의 접근법은 ALD 공정에서 통상적으로 사용되는 것보다 높은 기판 온도에서 작동시켜, 화학 기상 증착 공정을 유발할 수 있으나, 전구체의 순차적 도입의 장점을 여전히 가지며, 이러한 공정을 주기적 CVD라고 지칭될 수 있다.
본 개시의 일부 구현예에 따라, ALD 공정은 집적 회로 피가공물과 같은 기판 상에 루테늄-함유 막을 형성하기 위해 사용될 수 있다. 본 개시의 일부 구현예에서, 각각의 ALD 사이클은 두 개의 별개 증착 단계 또는 페이즈를 포함한다. 증착 사이클의 제1 페이즈("금속 페이즈")에서, 증착이 요구되는 기판 표면은 기판 표면 상에 화학 흡착하는 금속 전구체를 포함하는 제1 기상 반응물과 접촉되어, 기판 표면 상에 반응물 종의 대략 하나의 단분자 층만을 형성한다. 증착의 제2 페이즈("루테늄 페이즈")에서, 증착이 요구되는 기판 표면은 사산화루테늄을 포함한 제2 기상 반응물과 접촉되며, 여기서 사산화루테늄는 루테늄-백금 합금, 루테늄-팔라듐 합금, 또는 삼원 루테늄 산화물을 형성하기 위해 반응할 수 있다.
본 개시의 일부 구현예에서, 제1 기상 반응물은 본원에서 "금속 화합물"로도 본원에 지칭되는 금속 함유 전구체를 포함할 수 있다. 일부 구현예에서, 제1 기상 반응물은, 백금, 팔라듐, 알루미늄, 티타늄, 비스무스, 아연, 및 이들의 조합으로 이루어진 군으로부터 선택된 금속을 포함하는 금속유기 전구체를 포함할 수 있다. 일부 구현예에서, 금속유기 전구체는 주기율표 2족으로부터의 금속, 즉 알칼리 토금속이 없거나 실질적으로 없을 수 있다. 일부 구현예에서, 금속유기 전구체는 칼슘(Ca), 스트론튬(Sr) 및 바륨(Ba)으로 이루어진 군으로부터 선택된 금속이 없거나 실질적으로 없을 수 있다.
본 개시의 일부 구현예에서, 제1 기상 반응물은 본원에서 "금속 화합물"로도 본원에 지칭되는 금속 함유 전구체를 포함할 수 있다. 일부 구현예에서, 금속 함유 전구체는 0, +I, +II, +III, +IV, +V 또는 +VI의 산화 상태를 갖는 금속을 포함할 수 있다. 일부 구현예에서, 금속 함유 전구체 중 금속의 산화 상태는 +II 또는 +III일 수 있다. 일부 구현예에서, 금속 함유 전구체 중 금속의 산화 상태는 0이 아닐 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체는 금속유기 백금 전구체, 즉 백금 원소를 포함한 금속유기 전구체를 포함할 수 있다. 일부 구현예에서, 금속유기 백금 전구체는, (트리메틸)메틸시클로펜타디에닐 백금 또는 (트리메틸)시클로펜타디에닐((C5H5)Pt(CH3)3)과 같은 백금의 시클로펜타디에닐 화합물, Pt(아세틸아세토네이트)2와 같은 백금 베타디케토네이트 화합물, 또는 Pt(PF3)4, Pt(CO)2Cl2, 시스-[Pt(CH3)2((CH3)NC)2], 및 백금 헥사플루오로아세틸아세토네이트와 같은 기타 백금 화합물로 이루어진 군으로부터 선택될 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체는 금속유기 알루미늄 전구체, 즉 알루미늄 원소를 포함한 금속유기 전구체를 포함할 수 있다. 일부 구현예에서, 금속유기 알루미늄 전구체는 트리메틸알루미늄(TMA), 트리메틸알루미늄(TEA), 디메틸알루미늄 클로라이드(AlMe2Cl), 디메틸알루미늄 이소프로폭시드(AlMe2OPr) 또는 알루미늄 에톡시드((AlOEt)3) 중 적어도 하나를 포함할 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체는 금속유기 아연 전구체, 즉 아연 원소를 포함한 금속유기 전구체를 포함할 수 있다. 예를 들어, 금속유기 아연 전구체는 디메틸아연(ZnMe2), 디에틸아연(ZnEt2), 메틸아연 이소프로폭시드(ZnMe(OPr)), 또는 아연 아세테이트(Zn(CH)3CO2)2) 중 적어도 하나를 포함할 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체는 금속유기 팔라듐 전구체, 즉 팔라듐 원소를 포함한 금속유기 전구체를 포함할 수 있다. 일부 구현예에서, 금속유기 팔라듐 전구체는 Pd(thd)2 또는 Pd(Hfac)2 중 적어도 하나를 포함할 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체는 금속유기 티타늄 전구체, 즉 티타늄 원소를 포함한 금속유기 전구체를 포함할 수 있다. 일부 구현예에서, 금속유기 티타늄 전구체는 테트라키스디메틸아미노 티타늄(TDMAT), 테트라키스디에틸아미노 티타늄(TDEAT), 펜타메틸시클로펜타디에닐트리메톡시 티타늄(CpMe5Ti(OMe)3), 티타늄 메톡시드(Ti(OMe)4), 티타늄 에톡시드(Ti(OEt)4), 티타늄 이소프로폭시드(Ti(OPr)4), 또는 티타늄 부톡시드 (Ti(OBu)4) 중 적어도 하나를 포함할 수 있다. 금속유기 티타늄 전구체는 블롬베르그 등에게 승인된 미국 특허 제9,062,390호에 설명되어 있고, 본원에 참고로 포함된다.
본 개시의 일부 구현예에서, 금속유기 전구체는 금속유기 비스무스 전구체, 즉 비스무스 원소를 포함한 금속유기 전구체를 포함할 수 있다. 일부 구현예에서, 금속유기 비스무스 전구체는 비스무스-알콕시드 또는 비스무스-실릴아미도 중 적어도 하나를 포함할 수 있다. 일부 구현예에서, 금속유기 비스무스 전구체는 [(dmb)2Bi-O-Bi(dmb)2]2, 트리스(2,3-디메틸-2-부톡시)비스무스(III), 트리스(터트-부톡시)비스무스(III), 또는 트리(이소프로폭시)비스무스(III)로 이루어진 군으로부터 선택될 수 있다. 일부 구현예에서, 금속유기 비스무스 전구체는 Bi(N(SiMe3)2)3, Bi(thd)3, Bi(OtBu)3, Bi(dmb)3, 또는 Bi(CH2SiMe3)3 중 적어도 하나를 포함할 수 있다. 금속유기 비스무스 전구체는 하탄파 등에게 승인된 미국 특허 제7,713,584호에 설명되어 있고, 본원에 참고로 포함된다.
본 개시의 일부 구현예에서, 금속유기 전구체를 포함한 제1 기상 반응물과 상기 기판을 접촉시키는 단계는, 기판을 약 0.01 초 내지 약 60 초, 약 0.05 초 내지 약 10 초, 또는 약 0.1 초 내지 약 5.0 초의 시간 동안 금속유기 전구체에 노출시키는 단계를 포함할 수 있다. 또한, 금속 함유 전구체, 예를 들어 금속유기 전구체의 펄스화 중에 금속유기 전구체의 유량은 2000 sccm 미만, 또는 500 sccm 미만, 또는 100 sccm 미만, 또는 50 sccm 미만, 또는 10 sccm 미만, 또는 1 sccm 미만, 또는 심지어 0.1 sccm 미만일 수 있다. 또한, 기판 위로 금속유기 전구체를 펄스화하는 중에 금속유기 전구체의 유량은 약 0.05 내지 2000 sccm, 약 0.1 내지 1000 sccm, 또는 약 1 내지 약 500 sccm 범위일 수 있다.
과잉의 금속유기 전구체 및 반응 부산물(있는 경우)은 예를 들어, 불활성 가스로 펌핑함으로써 표면으로부터 제거될 수 있다. 예를 들어, 본 개시의 일부 구현예에서 상기 방법은 기판 표면이 대략 2.0 초 미만의 시간 동안 퍼지되는 퍼지 사이클을 포함할 수 있다. 과잉의 금속유기 전구체 및 임의의 반응 부산물은 반응 챔버와 유체 연통하는 펌핑 시스템에 의해 생성된 진공의 도움으로 제거될 수 있다.
증착 사이클의 제2 페이즈("사산화루테늄 페이즈")에서, 기판은 사산화루테늄(RuO4)을 포함한 제2 기상 반응물과 접촉할 수 있다. 본 발명의 일부 구현예에서, 사산화루테늄의 루테늄 성분은 +VIII 또는 적어도 +VII의 산화 상태를 가질 수 있다. 일부 구현예에서, 사산화루테늄의 루테늄 성분은 적어도 +III 또는 0보다 큰 산화 상태를 가질 수 있다.
본 개시의 일부 구현예에서, 사산화루테늄(RuO4)은, 예를 들어 불활성 유기 용매 또는 에틸-메틸-플루오르화 용매 혼합물과 같은 플루오로카본 용매 등의 용매에 용해될 수 있다. 일부 구현예에서, 용매 중의 사산화루테늄(RuO4) 농도(%w/w)는 0.01% 초과, 또는 0.1% 초과, 또는 0.5% 초과, 또는 1.0% 초과, 또는 심지어 1.5% 초과일 수 있다. 일부 구현예에서, 용매 중의 사산화루테늄(RuO4)의 농도(%w/w)는 100% 미만, 또는 50% 미만, 또는 20% 미만, 또는 10% 미만, 또는 5% 미만, 또는 2% 미만, 또는 심지어 1% 미만일 수 있다. 사산화루테늄(RuO4) 전구체 및 그 용도는 미국 특허 출원 제2010/0212021712호에 기술되어 있으며, 본원에 참조로 포함된다.
일부 구현예에서, 기판을 사산화루테늄(RuO4)에 노출시키는 단계는 기판 위로 사산화루테늄(RuO4) 전구체를 0.1 초 내지 2.0 초, 또는 약 0.01 초 내지 약 10 초, 또는 약 20 초 미만, 약 10 초 미만 또는 약 5 초 미만의 시간 동안 펄스화하는 단계를 포함할 수 있다. 사산화루테늄(RuO4) 전구체를 기판 위로 펄스화하는 동안, 사산화루테늄(RuO4) 전구체의 유량은 50 sccm 미만, 또는 25 sccm 미만, 또는 15 sccm 미만, 또는 10 sccm 미만일 수 있다. 본 개시의 일부 구현예에서, 사산화루테늄(RuO4)은 적절한 용매에 용해될 수 있고 용매에 용해된 사산화루테늄(RuO4)의 유량은 0.00001 sccm 내지 2000 sccm, 또는 0.001 sccm 내지 100 sccm, 또는 0.1 sccm 내지 20 sccm일 수 있다.
사산화루테늄(RuO4)을 포함한 제2 기상 반응물은, 기판 상에 남아 있는 금속-함유 분자와 반응할 수 있다. 일부 구현예에서, 제2 페이즈 전구체는 사산화루테늄(RuO4)을 포함할 수 있고, 이 반응은 루테늄-백금 합금, 루테늄-팔라듐 합금, 또는 루테늄 산화물을 증착할 수 있다.
과잉의 제2 기상 반응물(예, 사산화루테늄(RuO4)) 및 반응 부산물이 존재하는 경우, 이들은 예를 들어 퍼지 가스 펄스 및/또는 펌핑 시스템에 의해 발생된 진공에 의해 기판 표면으로부터 제거될 수 있다. 퍼지 가스는 임의의 불활성 가스, 예를 들어 아르곤(Ar), 질소(N2) 또는 헬륨(He)인 것이 바람직하며 이들로 제한되지는 않는다. 퍼지(즉, 퍼지 가스 펄스) 또는 다른 반응물 제거 단계가 개재되는 경우, 하나의 페이즈는 일반적으로 다른 페이즈를 바로 따르는 것으로 간주된다.
기판이 제1 기상 반응물(예, 금속유기 전구체) 및 제2 기상 반응물(예, 사산화루테늄(RuO4))과 교대로 접촉되는 증착 사이클은, 원하는 두께의 루테늄-함유 막이 증착될 때까지 2회 이상 반복될 수 있다. 본 개시의 일부 구현예에서, 기판이 제1 기상 반응물 및 제2 기상 반응물과 접촉하는 순서는, 기판이 제2 기상 반응물과 먼저 접촉하고 이어서 제1 기상 반응물과 접촉하는 순서일 수 있음을 이해해야 한다. 추가적으로, 일부 구현예에서, 주기적 증착 공정은 기판이 제1 기상 반응물(즉, 금속유기 전구체)과 1회 이상 접촉하고 이어서 기판이 제2 기상 반응물(즉, 사산화루테늄(RuO4))과 1회 이상 접촉하는 것을 포함할 수 있으며, 유사하게 기판이 제2 기상 반응물과 1회 이상 접촉하고 이어서 기판이 제1 기상 반응물과 1회 이상 접촉하는 것을 교대로 포함할 수 있다. 또한, 본 개시의 일부 구현예는 비-플라즈마 반응물, 예를 들어 이온화된 반응성 종이 실질적으로 없는 제1 기상 반응물 및 제2 기상 반응물을 포함할 수 있다. 일부 구현예에서, 제1 기상 반응물 및 제2 기상 반응물은 이온화된 반응성 종, 여기 종 또는 라디칼 종이 실질적으로 없다. 예를 들어, 제1 기상 반응물 및 제2 기상 반응물은 모두 비-플라즈마 반응물을 포함할 수 있어서 하부 기판의 이온화 손상 및 이로 인해 발생하는 관련 결함을 방지한다.
루테늄-백금 합금, 루테늄-팔라듐 합금, 또는 삼원 루테늄 산화물 중 적어도 하나를 증착하기 위해, 금속유기 전구체와 사산화루테늄(RuO4)을 이용한 본원에 기술된 주기적 증착 공정은, 가열된 기판을 갖는 ALD 또는 CVD 증착 시스템에서 수행될 수 있다. 예를 들어, 일부 구현예에서, 방법은 기판을 약 80℃ 내지 약 150℃의 온도로 가열하는 단계, 또는 심지어 기판을 대략 80℃ 내지 약 120℃의 온도로 가열하는 단계를 포함할 수 있다. 물론, 임의의 주어진 주기적 증착 공정의 적합한 온도 범위, 예를 들어 ALD 반응과 같은 적절한 온도 범위는 관련된 표면 종결부 및 반응물 종에 의존할 것이다. 본원에서, 온도는 사용되는 전구체에 따라 변하며, 일반적으로 약 700℃ 이하이다. 일부 구현예에서 증착 온도는 기상 증착 공정에서 일반적으로 약 100℃ 이상이고, 일부 구현예에서 증착 온도는 약 100℃ 내지 약 250℃이고, 일부 구현예에서 증착 온도는 약 120℃ 내지 약 200℃이다. 일부 구현예에서 증착 온도는 약 500℃ 미만, 약 400℃ 미만 또는 약 300℃ 미만이다. 일부 예에서 증착 온도는 약 200℃ 미만, 약 150℃ 미만 또는 약 100℃ 미만일 수 있다. 일부 예에서 증착 온도는 약 20℃ 이상, 약 50℃ 이상 및 약 75℃ 이상일 수 있다. 본 개시의 일부 구현예에서, 증착 온도, 즉 증착 동안의 기판의 온도는 약 150℃이다.
일부 구현예에서, 루테늄-함유 막의 성장 속도는 약 0.005 Å/사이클 내지 약 5 Å/사이클, 약 0.01 Å/사이클 내지 약 2.0 Å/사이클이다. 일부 구현예에서, 루테늄-함유 막의 성장 속도는 약 0.05 Å/사이클 초과, 약 0.1 Å/사이클 초과, 약 0.15 Å/사이클 초과, 약 0.20 Å/사이클 초과, 약 0.25 Å/사이클 초과, 또는 약 0.3 Å/사이클 초과이다. 일부 구현예에서, 루테늄-함유 막의 성장 속도는 약 2.0 Å/사이클 미만, 약 1.0 Å/사이클 미만, 약 0.75 Å/사이클 미만, 약 0.5 Å/사이클 미만 또는 약 0.2 Å/사이클 미만이다. 일부 구현예에서, 루테늄-함유 막의 성장 속도는 0.01 Å/사이클 내지 100 Å/사이클일 수 있다. 일부 구현예에서, 루테늄-함유 막의 성장 속도는 0.01 Å/사이클 내지 10 Å/사이클, 또는 0.05 Å/사이클 내지 5 Å/사이클, 또는 0.1 Å/사이클 내지 1 Å/사이클일 수 있다. 본 개시의 일부 구현예에서 루테늄-함유 막의 성장 속도는 대략 10 Å/사이클일 수 있다.
본 개시의 구현예는, 도 1의 예시적인 방법(100)에 의해 보다 상세하게 나타낼 수 있는 주기적 증착을 포함할 수 있다. 방법(100)은, 적어도 하나의 기판을 반응 챔버 내에 제공하고 기판을 증착 온도로 가열하는 단계를 포함하는 공정 블록(110)으로 시작할 수 있고, 예를 들어 기판은 벌크 실리콘 기판을 포함할 수 있고, 반응 챔버는 원자층 증착 반응 챔버를 포함할 수 있고 기판은 약 150℃의 증착으로 가열될 수 있다. 방법(100)은 기판을 금속 함유 기상 반응물과 접촉시키는 단계를 포함하는 공정 블록(120)으로 계속할 수 있으며, 예를 들어 기판은 금속유기 전구체와 약 1 초의 시간 동안 접촉될 수 있다. 기판을 금속유기 함유 전구체와 접촉시킬 시, 과잉의 금속유기 함유 전구체 및 임의의 반응 부산물은 퍼지/펌프 공정에 의해 반응 챔버로부터 제거될 수 있다. 방법(100)은 약 4 초의 시간 동안 기판을 사산화루테늄(RuO4)과 접촉시키는 것을 포함하는 공정 블록(130)으로 계속할 수 있다. 기판을 사산화루테늄(RuO4) 전구체와 접촉시킬 시, 과잉의 RuO4 전구체 및 임의의 반응 부산물은 퍼지/펌프 공정에 의해 반응 챔버로부터 제거될 수 있다.
기판이 교대 순차적으로 금속유기 전구체와 접촉하고 사산화루테늄(RuO4) 전구체와 접촉되는 방법은, 하나의 증착 사이클을 구성할 수 있다. 본 개시의 일부 구현예에서, 루테늄-함유 막을 증착하는 방법은 증착 사이클을 1회 이상 반복하는 단계를 포함할 수 있다. 예를 들어, 방법(100)은 결정 게이트(140)로 계속할 수 있는데, 여기서 결정 게이트는 방법(100)이 계속되거나 종료되는지를 판단한다. 공정 블록(140)의 결정 게이트는 증착된 루테늄-함유 막의 두께에 기반하여 결정되고, 예를 들어 금속 함유 막의 두께가 원하는 소자 구조에 대해 불충분한 경우, 그 다음에 방법(100)은 공정 블록(120)으로 다시 돌아갈 수 있고 기판을 금속유기 전구체와 접촉시키고 기판을 사산화루테늄(RuO4) 전구체와 접촉시키는 공정을 1회 이상 반복할 수 있다. 일단 루테늄-함유 막이 원하는 두께로 증착되면, 이 방법은 종료(150)될 수 있고, 루테늄-함유 막은 소자 구조를 형성하기 위한 추가적인 공정을 거칠 수 있다.
본 개시의 일부 구현예에서, 방법(100)은 루테늄 함량, 즉 본 개시의 구현예에 의해 증착된 루테늄-함유 막에서의 루테늄 원자%를 제어하기 위해 이용될 수 있는, 추가적인 처리 단계를 포함할 수 있다. 일부 구현예에서, 기판을 유기금속 전구체와 접촉시킨 이후에 그리고 기판을 사산화루테늄과 접촉시키기 이전에, 제1 추가 처리 단계를 수행할 수 있다. 일부 구현예에서, 제1 추가 처리 단계는 기판을, 예를 들어 산소 분자(O2)의 여기에 의해 생성된 플라즈마와 접촉시키는 단계를 포함할 수 있다. 본 개시의 일부 구현예에서, 기판을 산소 함유 플라즈마에 노출시키는 단계는, 본 개시의 방법에 의해 증착된 루테늄-함유 층에서 루테늄 함량을 감소시킬 수 있다. 일부 구현예에서, 기판을 금속유기 전구체와 접촉시킨 이후에 그리고 기판을 사산화루테늄과 접촉시키기 이전에, 제2 추가 처리 단계를 수행할 수 있다. 일부 구현예에서, 제2 추가 처리 단계는, 예를 들어 알코올, 알데히드, 또는 카르복실 산과 같은 추가 유기 전구체와 기판을 접촉시키는 단계를 포함할 수 있다.
본 개시의 일부 구현예에서, 추가적인 유기 전구체는 알코올을 포함할 수 있으며, 상기 알코올은 일차 알코올, 이차 알콜, 삼차 알콜, 폴리히드록시 알콜, 환형 알콜 방향족 알콜, 및 다른 알코올의 유도체일 수 있다.
본 개시의 일부 구현예에서, 추가적인 유기 전구체는, 일반 조성식(I)을 갖는 화합물, 일반 조성식(II)을 갖는 알칸디알 화합물, 및 할로겐화된 알데히드 및 다른 알데히드 유도체로 구성되는 군으로부터 선택된, 적어도 하나의 알데히드 기(-CHO)를 포함할 수 있다.
따라서, 일부 구현예에서, 추가적인 유기 전구체는 다음 일반 조성식을 갖는 알데히드를 포함할 수 있다.
R3-CHO (I)
여기서, R3는 수소, 및 메틸, 에틸, 프로필, 부틸, 펜틸, 또는 헥실과 같은 선형 또는 분지형 C1 - C20 알킬 또는 알케닐기로 구성된 군으로부터 선택된다. 일부 구현예에서, R3은 메틸 또는 에틸로 구성되는 군으로부터 선택된다. 조성식(I)에 따라 예시적이나 이에 제한되지 않는 화합물은, 포름알데히드, 아세트알데히드 및 부틸알데히드이다.
본 개시의 일부 구현예에서, 추가적인 유기 전구체는 다음 일반 조성식(II)을 갖는 알데히드를 포함할 수 있다.
OHC-R4-CHO (II)
여기서, R4는 선형 또는 분지형 C1-C20 포화 또는 불포화 탄화수소이다. 대안적으로, 알데히드 기는 서로 직접 결합될 수 있다(R4는 없음).
본 개시의 일부 구현예에서, 추가적인 유기 전구체는 적어도 하나의 -COOH 기를 포함할 수 있고, 일반 조성식(III)의 화합물, 폴리카르복시 산, 할로겐화된 카르복시 산 및 카르복시 산의 다른 유도체로 구성되는 군으로부터 선택될 수 있다. 따라서, 일부 구현예에서, 추가적인 유기 전구체는 다음 일반 조성식(III)을 갖는 카르복시 산을 포함할 수 있다.
R5-COOH (III)
여기서, R5는 수소, 또는 메틸, 에틸, 프로필, 부틸, 펜틸, 또는 헥실과 같은 선형 또는 분지형 C1-C20 알킬 또는 알케닐기이고, 예를 들어 메틸 또는 에틸이다. 일부 구현예에서, R5는 선형 또는 분지형 C1-C3 알킬기 또는 알케닐기이다. 조성식(III)에 따른 화합물의 예는 포름 산, 프로판 산 및 아세트 산이다.
본 개시의 일부 구현예에서, 추가적인 유기 전구체에 대한 기판의 노출은, 증착된 막에서 금속 유기물에 의해 공급된 금속에 비해 루테늄-함유 층 내의 루테늄 함량을 증가시킬 수 있다.
본 개시의 일부 구현예에서, 특히 개시된 증착 방법이 삼원 루테늄 산화물을 증착하기 위해 사용되는 구현예에서, 기판은 증착 공정 이전에 표면 전처리를 겪을 수 있다. 일부 구현예에서, 기판의 표면은 알코올로 전처리되어 기판 표면 상의 탄소량을 증가시킬 수 있다. 예를 들어, 기판은 C1-C10 알코올, C2-C10 디올 및 C3-C10 트리올로 이루어진 군으로부터 선택된 알코올로 전처리될 수 있다. 본 개시의 일부 구현예에서, 기판 표면은 메탄올, 에탄올, 이소프로판올, 또는 CxHy 기를 함유한 다른 유기 분자 중 적어도 하나로 전처리될 수 있고, 이들은 상기 기판의 표면 상에 화학 흡착할 수 있다.
본 개시의 일부 구현예에서, 본 개시의 방법은, 적절한 기판 상에 루테늄 함유 막, 예컨대 순수 루테늄을 증착하기 위해 사용될 수 있다. 일부 구현예에서, 기판 상의 루테늄-함유 막의 핵생성은 지연될 수 있으며, 즉, 증착이 일어나지 않는 인큐베이션 기간이 있다. 예를 들어, 실리콘 산화물 표면 상의 루테늄 증착을 위해, 막을 증착하기 이전에 100 회 초과의 증착 사이클의 인큐베이션 사이클이 존재할 수 있다. 인큐베이션 기간을 개선하고 루테늄-함유 막의 신속한 핵생성을 허용하기 위해, 기판을 증착 전에 처리할 수 있다. 따라서, 본 개시의 일부 구현예에서, 기판 표면은 유기 분자로 처리되어 인큐베이션 시간을 줄이고 루테늄-함유 막의 핵생성을 증가시킬 수 있다. 일부 구현예에서, 유기 분자는 알코올, 또는 예를 들어 트리메틸알루미늄(TMA)과 같은 금속유기를 포함할 수 있다. 예를 들어, 기판 표면은 실리콘 산화물 표면을 포함할 수 있고, 상기 실리콘 산화물 표면은 기판을 루테늄 전구체와 접촉시키기 전에 트리메틸 알루미늄(TMA)에 노출될 수 있다. 트리메틸 알루미늄(TMA)을 이용해 실리콘 산화물 표면 상에 이러한 전처리를 하면, 인큐베이션 시간을 크게 감소시키고 루테늄-함유 막, 예컨대 사산화루테늄(RuO4)과 수소(H2) 증착 공정을 통한 순수 루테늄의 빠른 핵생성을 허용한다.
본원에 설명된 일부 구현예에 따라, 증착된 루테늄-함유막, 예컨대 루테늄-백금 합금, 루테늄-팔라듐 합금, 또는 삼원 루테늄 산화물은 연속적인 박막일 수 있다. 일부 구현예에서, 본원에 설명된 구현예 중 일부에 따라 증착된 루테늄-함유 막을 포함한 박막은 약 100 nm 미만, 약 60 nm 미만, 약 50 nm 미만, 약 40 nm 미만, 약 30 nm 미만, 약 25 nm 미만, 또는 약 20 nm 미만 또는 약 15 nm 미만 또는 약 10 nm 미만 또는 약 5 nm 미만 또는 그 이하의 두께에서 연속일 수 있다. 본원에서 지칭하는 연속성은 물리적으로 연속성이거나 전기적으로 연속성일 수 있다. 일부 구현예에서, 막이 물리적으로 연속성일 수 있는 두께는 막이 전기적으로 연속성인 두께와 동일하지 않을 수 있으며, 막이 전기적으로 연속성일 수 있는 두께는 막이 물리적으로 연속성인 두께와 동일하지 않을 수 있다.
일부 구현예에서, 본원에 설명된 구현예 중 일부에 따라 증착된 루테늄-함유 막은 약 20 nm 내지 약 100 nm의 두께를 가질 수 있다. 일부 구현예에서, 본원에 설명된 구현예 중 일부에 따라 증착된 루테늄-함유 막은 약 20 nm 내지 약 60 nm의 두께를 가질 수 있다. 일부 구현예에서, 본원에 설명된 구현예 중 일부에 따라 증착된 루테늄-함유 막은 약 20 nm 초과, 약 30 nm 초과, 약 40 nm 초과, 약 50 nm 초과, 약 60 nm 초과, 약 100 nm 초과, 약 250 nm 초과, 약 500 nm 초과, 또는 그 이상의 두께를 가질 수 있다. 일부 구현예에서, 본원에 설명된 구현예 중 일부에 따라 증착된 루테늄-함유 막은 약 50 nm 미만, 약 30 nm 미만, 약 20 nm 미만, 약 15 nm 미만, 약 10 nm 미만, 약 5 nm 미만, 약 3 nm 미만, 약 2 nm 미만, 또는 심지어 약 1 nm 미만의 두께를 가질 수 있다.
본 개시의 구현예에 따라 루테늄-함유 막은, 고 종횡비 특징을 포함한 3차원 구조 상에 증착될 수 있다. 일부 구현예에서, 루테늄-함유 막의 단차 피복도는, 약 2 초과, 5 초과, 약 10 초과, 약 25 초과, 약 50 초과, 또는 심지어 약 100 초과의 종횡비(높이/폭)를 갖는 구조에서 약 50% 이상, 약 80% 이상, 약 90% 이상, 약 95% 이상, 약 98% 이상 또는 약 99% 이상일 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체는 금속유기 백금 전구체를 포함할 수 있고, 본 개시의 방법에 의해 증착된 루테늄-함유 막은 루테늄-백금 합금을 포함할 수 있다. 일부 구현예에서, 루테늄-백금 합금은 5 원자% 초과, 또는 10 원자% 초과, 또는 15 원자% 초과, 또는 25 원자% 초과, 또는 50 원자% 초과, 또는 75 원자% 초과, 또는 심지어 90 원자% 초과의 백금 함량을 포함할 수 있다. 일부 구현예에서, 루테늄-백금 합금은 대략 15 원자%의 백금 함량을 포함할 수 있다.
추가적인 구현예에서, 루테늄-백금 합금은 약 20 원자% 미만의 산소, 약 10 원자% 미만의 산소, 약 5 원자% 미만의 산소, 또는 심지어 약 2 원자% 미만의 산소를 포함할 수 있다. 다른 구현예에서, 루테늄-백금 합금은 약 10 원자% 미만의 수소, 약 5 원자% 미만의 수소, 또는 약 2 원자% 미만의 수소, 또는 심지어 약 1 원자% 미만의 수소를 포함할 수 있다. 또 다른 구현예에서, 루테늄-백금 합금은 약 10 원자% 미만의 탄소, 약 5 원자% 미만의 탄소, 또는 약 2 원자% 미만의 탄소, 또는 약 1 원자% 미만의 탄소, 또는 심지어 약 0.5 원자% 미만의 탄소를 포함할 수 있다. 본원에 개요된 구현예에서, 원소의 원자 농도는 러더퍼드 후방 산란(RBS)을 활용하여 결정될 수 있다.
본원에 개시된 주기적 증착 공정에 의해 증착된 루테늄-백금 합금은, 예를 들어 연료 전지용 애노드 촉매 및 반도체 트랜지스터 응용을 위한 일함수 금속과 같이, 다양한 상황에 이용될 수 있다.
보다 상세하게는, 본 개시의 방법에 의해 증착된 루테늄-백금 합금은, 직접식 메탄올 연료 전지(DMFC)의 애노드 촉매와 같은 전극으로 이용될 수 있다. DMFC는, 수성 메탄올 용액의 산화가 애노드에서 일어나는, 널리 공지된 멤브레인 전기화학 발전기이다. DMFC는 다른 유형의 저온 연료 전지와 비교하면 매우 매력적이고, 액체 연료를 사용하고, 이는 에너지 밀도의 측면에서 뛰어난 이점을 제공하고 로드 또는 리필하는 것이 훨씬 더 쉽고 더 빠르다. 많은 연구가 애노드 촉매 개선에 집중되며, 백금 및 루테늄 합금은 촉매 활성 측면에서 상당히 바람직하다. 그러나, 백금과 루테늄은, 종래의 형성 방법을 이용하여 실제 합금으로 결합하기가 매우 어렵고, 따라서 본 개시는 고품질의 루테늄-백금 합금의 형성을 위한 방법을 제공한다. 예를 들어, 본 개시의 일부 구현예에서, 루테늄-백금 합금은 연료 전지 장치에서 사용하기 위한 촉매 애노드를 형성하기 위해, 예를 들어 탄소 지지체와 같은 불활성 지지체 상에 증착될 수 있다.
본 개시의 일부 구현예에서, 본원의 방법에 의해 증착된 루테늄-백금 합금은, 예를 들어 평면 트랜지스터 구조 또는 FinFET와 같은 다중 게이트 트랜지스터와 같은 트랜지스터 구조에서 일함수 금속으로서 이용될 수 있다. 보다 상세하게 그리고 도 2를 참조하면, 반도체 소자 구조(200)는 반도체 몸체(216) 및 반도체 몸체(216) 위에 배치된 루테늄-백금 합금을 포함하는 게이트 전극(210)을 포함할 수 있다. 일부 구현예에서, 반도체 소자 구조(200)는 트랜지스터 구조를 포함할 수 있고 소스 영역(202), 드레인 영역(204), 및 그 사이의 채널 영역(206)을 또한 포함할 수 있다. 트랜지스터 게이트 구조(208)는 전극(210) 즉, 게이트 전극을 포함할 수 있고, 이는 게이트 유전체(212)에 의해 채널 영역(206)과 분리될 수 있다. 본 발명에 따라 게이트 전극(210)은 예를 들어, 본원에 기술된 주기적 증착 공정에 의해 증착된 루테늄-백금 합금을 포함할 수 있다. 도 2에 나타낸 바와 같이, 일부 구현예에서의 트랜지스터 게이트 구조(208)는 게이트 전극(210) 상에 형성된, 하나 이상의 추가적인 전도층(214)을 더 포함할 수 있다. 하나 이상의 추가적인 전도층(214)은 폴리실리콘, 내화 금속, 전이 금속 탄화물 및 전이 금속 질화물 중 적어도 하나를 포함할 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체는 알루미늄, 티타늄, 비스무스, 아연 및 이들의 조합으로 이루어진 군으로부터 선택된 금속을 포함할 수 있고, 본 개시의 방법은 삼원 루테늄 산화물을 증착하는 단계를 포함할 수 있다. 예를 들어, 본원에 개시된 주기적 증착 방법은 일반 조성식 MxRuyOz의 삼원 루테늄 산화물의 증착을 위해 이용될 수 있고, 여기서 M은 알루미늄, 티타늄, 비스무스, 아연 및 이들의 조합의 군으로부터 선택된 금속이고, Ru는 루테늄이고, O는 산소이다. 따라서, 본 개시의 구현예는 알루미늄 루테늄 산화물(AlxRuyOz), 티타늄 루테늄 산화물(TixRuyOz), 비스무스 루테늄 산화물(BixRuyOz) 및 아연 루테늄 산화물(ZnxRuyOz) 중 적어도 하나를 증착하기 위해 사용될 수 있다.
본 개시의 일부 구현예에서, 삼원 루테늄 산화물(MxRuyOz)은 금속 함량, 즉 M의 원자%를 포함할 수 있고, 이는 1 원자%보다 크거나, 10 원자%보다 크거나, 15 원자%보다 큰, 또는 심지어 20 원자%보다 크다. 본 개시의 일부 구현예에서, 삼원 루테늄 산화물(MxRuyOz)은 루테늄 함량, 즉 Ru의 원자%를 포함할 수 있고, 이는 1 원자%보다 크거나, 10 원자%보다 크거나, 15 원자%보다 큰, 또는 심지어 20 원자%보다 크다. 본 개시의 일부 구현예에서, 삼원 루테늄 산화물(MxRuyOz)은 산소 함량, 즉 O의 원자%를 포함할 수 있고, 이는 20 원자%보다 크거나, 40 원자%보다 크거나, 60 원자%보다 큰, 또는 심지어 65 원자%보다 크다.
추가 구현예에서, 삼원 루테늄 산화물은 약 5 원자% 미만의 수소, 약 2 원자% 미만의 수소, 또는 심지어 약 1 원자% 미만의 수소를 포함할 수 있다. 또 다른 구현예에서, 삼원 루테늄 산화물은 약 10 원자% 미만의 탄소, 약 5 원자% 미만의 탄소, 또는 약 2 원자% 미만의 탄소, 또는 약 1 원자% 미만의 탄소, 또는 심지어 약 0.5 원자% 미만의 탄소를 포함할 수 있다. 본원에 개요된 구현예에서, 원소의 원자 농도는 러더퍼드 후방 산란(RBS)을 활용하여 결정될 수 있다.
본원에 개시된 주기적 증착 공정에 의해 증착된 삼원 루테늄 산화물(MxRuyOz)을, 예를 들어 연료 전지 응용 분야와 같이 다양한 상황에 사용할 수 있다. 예를 들어, 티타늄 루테늄 산화물(TixRuyOz)은 수소 연료 전지 적용을 위한 안정적인 촉매로서 활용될 수 있으며, 여기서 티타늄 루테늄 산화물은 일반적으로 사용되는 탄소 지지체를 대체하고 백금 나노입자는 촉매 물질로서 지지체 상에 증착된다. 또한, 비스무스 루테늄 산화물(BixRuyOz)은 고체 산화물 연료 전지에서 적합한 전극 물질로서 사용될 수 있다.
본 개시의 일부 구현예에서, 금속유기 전구체를 포함한 제1 기상 반응물은, 리튬, 칼슘, 바륨, 코발트, 납 및 이들의 조합의 군으로부터 선택된 금속을 추가로 포함할 수 있다. 일부 구현예에서, 금속유기 전구체는 리튬 금속을 포함할 수 있고 증착된 막은 리튬 루테늄 산화물을 포함할 수 있다. 예를 들어, 리튬 루테늄 산화물은 리튬 이온 배터리 응용예에서 전극 재료로서 사용될 수 있다. 일부 구현예에서, 금속유기 전구체는 칼슘 금속을 포함할 수 있고, 증착된 막은 칼슘 루테늄 산화물을 포함할 수 있다. 예를 들어, 칼슘 루테늄 산화물은 산소 발생 애노드로서 전기화학 응용 분야에서 사용될 수 있다. 일부 구현예에서, 금속유기 전구체는 바륨 금속을 포함할 수 있고, 증착된 막은 바륨 루테늄 산화물을 포함할 수 있다. 예를 들어, 바륨 루테늄 산화물은 이종 촉매 구조에서 사용될 수 있다. 일부 구현예에서, 금속유기 전구체는 코발트 금속을 포함할 수 있고, 증착된 막은 코발트 루테늄 산화물을 포함할 수 있다. 예를 들어, 코발트 루테늄 산화물은 서미스터 소자 구조에서 사용될 수 있다. 일부 구현예에서, 금속유기 전구체는 납 금속을 포함할 수 있고, 증착된 막은 납 루테늄 산화물을 포함할 수 있다. 예를 들어, 납 루테늄 산화물은, 리튬 기반 배터리용 전극, 고체 산화물 연료 전지의 캐소드 재료, 및 알코올의 선택적 산화를 포함하나 이에 제한되지 않는 다수의 응용에서 사용될 수 있다.
본 개시의 일부 구현예에서, 본원에 개시된 공정에 의해 증착된 루테늄-함유 막은 이종 촉매로서 활용될 수 있고, 상기 루테늄-함유 막은 이종 촉매 구조의 적어도 일부를 포함할 수 있다. 예를 들어, 루테늄-함유 막은 촉매 지지체와 같은 적절한 기판 위에 증착될 수 있다. 일부 구현예에서, 촉매 지지체는 루테늄-함유 막이 증착되는, 표면적이 큰 지지체를 포함할 수 있다. 예를 들어, 촉매 지지체는 탄소, 알루미나 및 실리카를 포함할 수 있고, 촉매 지지체의 표면적을 증가시키기 위해, 그리고 이에 따라 이종 촉매의 활성을 증가시키기 위해, 촉매 지지체는 분말을 포함할 수 있다. 본 개시의 구현예에 따라 증착된 루테늄-함유 막을 포함한 이종 촉매 구조는, 예를 들어 기상 산화, 선택적 수소화, 및 연료 전지 전원 응용과 같이 다수의 화학 공정을 향상시키기 위해 사용될 수 있다.
본 개시의 구현예는, 본 개시의 루테늄-함유 막을 형성하도록 구성된 반응 시스템을 또한 포함할 수 있다. 보다 상세하게, 도 3은 소정의 압력, 온도, 및 주변 조건 하에서 기판(미도시)을 유지하기 위한, 그리고 다양한 가스에 기판을 선택적으로 노출시키기 위한 메커니즘을 추가로 포함한 반응 챔버(302)를 포함하는 반응 시스템(300)을 개략적으로 나타낸다. 전구체 반응물 공급원(304)은 도관 또는 다른 적절한 수단(304A)에 의해 반응 챔버(302)에 결합될 수 있고, 매니폴드, 밸브 제어 시스템, 질량 흐름 제어 시스템, 또는 메커니즘에 추가로 결합되어 전구체 반응물 공급원(304)으로부터 나오는 가스 전구체를 제어한다. 전구체 반응물 공급원(304)에 의해 공급되는 전구체(미도시), 즉 반응물(미도시)은 상온 및 표준 대기압 조건에서 액체 또는 고체일 수 있다. 이러한 전구체는, 전구체 공급원 챔버 내에서의 기화 온도 또는 그 이상으로 유지될 수 있는 반응물 공급원 진공 용기 내에서 기화될 수 있다. 이러한 구현예에서, 기화된 전구체를 캐리어 가스(예, 비활성 또는 불활성 가스)와 함께 이동시킨 후 도관(304A)을 통해 반응 챔버(302) 내로 공급시킬 수 있다. 다른 구현예에서, 전구체는 표준 조건 하의 증기일 수 있다. 이러한 구현예에서, 전구체는 기화될 필요가 없으며, 캐리어 가스를 필요로 하지 않을 수 있다. 예를 들어, 일 구현예에서 전구체는 가스 실린더 내에 저장될 수 있다. 반응 시스템(300)은 전구체 반응물 공급원(306)과 같은 추가적인 전구체 반응물 공급원을 또한 포함할 수 있는데, 전술한 바와 같이 도관(306A)에 의해 반응 챔버에 또한 결합될 수 있다.
퍼지 가스 공급원(308)은 도관(308A)을 통해 반응 챔버(302)에 결합될 수도 있고 다양한 불활성 또는 귀 가스를 반응 챔버(302)에 선택적으로 공급하여 반응 챔버로부터 전구체 가스 또는 폐기 가스의 제거를 돕는다. 공급할 수 있는 다양한 불활성 또는 귀 가스는 고체, 액체 또는 저장된 가스 형태일 수 있다.
도 3의 반응 시스템(300)은 또한, 반응 시스템(300)에 포함된 밸브, 매니폴드, 펌프 및 기타 설비를 선택적으로 작동시키기 위한 전자 회로 및 기계적 구성 요소를 제공하는 시스템 작동 및 제어 메커니즘(310)을 포함할 수 있다. 이러한 회로 및 구성 요소는 전구체, 퍼지 가스를 각각의 전구체 공급원(304, 306) 및 퍼지 가스 공급원(308)으로부터 도입하기 위해 작동한다. 시스템 작동 및 제어 메커니즘(310)은 또한 가스 펄스 순서의 시점, 기판과 반응 챔버의 온도, 및 반응 챔버의 압력, 및 반응 시스템(300)의 적절한 작동을 제공하는데 필요한 다양한 기타 작동을 제어한다. 반응 챔버(302) 내로 그리고 반응 챔버로부터의 전구체, 반응물 및 퍼지 가스의 유동을 제어하기 위해, 작동 및 제어 메커니즘(310)은 제어 소프트웨어 및 전기식 혹은 공압식으로 제어되는 밸브를 포함할 수 있다. 제어 시스템은, 소프트웨어 또는 하드웨어 구성 요소, 예를 들어 특정 작업을 수행하는 FPGA 또는 ASIC과 같은 모듈을 포함할 수 있다. 유리하게는, 모듈은 제어 시스템의 어드레스 가능한 저장 매체에 탑재되어 하나 이상의 공정을 실행하도록 구성될 수 있다.
당업자는, 상이한 수 및 종류의 전구체 반응물 공급원 및 퍼지 가스 공급원을 포함하여 본 반응 시스템의 다른 구성이 가능함을 이해한다. 추가적으로, 당업자는, 가스를 반응 챔버(302) 내로 선택적으로 공급하는 목적을 달성하기 위해 사용될 수 있는 밸브, 도관, 전구체 공급원, 퍼지 가스 공급원의 다수의 배열이 존재함을 또한 이해할 것이다. 또한, 반응 시스템을 개략적으로 표현하면서, 많은 구성 요소가 예시의 단순화를 위해 생략되었는데, 이러한 구성 요소는, 예를 들어 다양한 밸브, 매니폴드, 정화기, 히터, 용기, 벤트, 및/또는 바이패스를 포함할 수 있다.
위에 설명된 본 발명의 예시적 구현예는 본 발명의 구현예의 예시일 뿐이기 때문에 이들 구현예는 첨부된 청구범위 및 그의 법적 균등물에 의해 정의되는 본 발명의 범주를 제한하지 않는다. 임의의 균등한 구현예는 본 발명의 범주 내에 있도록 의도된다. 확실하게, 본원에 나타내고 설명된 것 외에도, 설명된 요소의 대안적인 유용한 조합과 같이, 본 개시의 다양한 변경은 설명으로부터 당업자에게 분명할 수 있다. 이러한 변경예 및 구현예도 첨부된 청구범위의 범주 내에 있는 것으로 의도된다.

Claims (27)

  1. 주기적 증착 공정에 의해 기판 상에 루테늄-함유 막을 증착하기 위한 방법으로서, 상기 방법은,
    백금, 팔라듐, 알루미늄, 티타늄, 비스무스, 아연, 및 이들의 조합으로 이루어진 군으로부터 선택된 금속을 포함한 금속유기 전구체를 포함하는 제1 기상 반응물과 상기 기판을 접촉시키는 단계;
    상기 제1 기상 반응물과 상기 기판을 접촉시킨 후에 추가적인 유기 전구체를 포함하는 제3 기상 반응물을 상기 기판과 접촉시키는 단계; 및
    사산화루테늄(ruthenium tetroxide)을 포함한 제2 기상 반응물과 상기 기판을 접촉시키는 단계를 포함하되,
    상기 루테늄-함유 막은 루테늄-백금 합금, 루테늄-팔라듐 합금, 또는 삼원 루테늄 산화물 중 적어도 하나를 포함하는, 방법.
  2. 삭제
  3. 삭제
  4. 제1항에 있어서, 상기 방법은, 상기 기판이 상기 제1 기상 반응물 및 상기 제2 기상 반응물과 교대로 순차적으로 접촉되는 적어도 하나의 증착 사이클을 포함하는, 방법.
  5. 삭제
  6. 제1항에 있어서, 상기 금속유기 전구체는, (트리메틸)메틸시클로펜타디에닐 백금, (트리메틸)시클로펜타디에닐((C5H5)Pt(CH3)3), Pt(아세틸아세토네이트)2, Pt(PF3)4, Pt(CO)2Cl2, 시스-[Pt(CH3)2((CH3)NC)2], 및 백금 헥사플루오로아세틸아세토네이트로 이루어진 군으로부터 선택된 금속유기 백금 전구체를 포함하는, 방법.
  7. 삭제
  8. 제1항에 있어서, 상기 금속유기 전구체는, Pd(thd)2 및 Pd(hfac)2로 이루어진 군으로부터 선택된 금속유기 팔라듐 전구체를 포함하는, 방법.
  9. 삭제
  10. 제1항에 있어서, 상기 금속유기 전구체는, 테트라키스(디메틸아미도) 티타늄(TDMAT), 펜타메틸시클로펜타디에닐트리메톡시 티타늄(CpMe5Ti(OMe)3), 티타늄 메톡시드(Ti(OMe)4), 티타늄 에톡시드(Ti(OEt)4), 티타늄 이소프로폭시드 (Ti(OPr)4), 또는 티타늄 부톡시드(Ti(OBu)4)로 이루어진 군으로부터 선택된 금속유기 티타늄 전구체를 포함하는, 방법.
  11. 삭제
  12. 제1항에 있어서, 상기 금속유기 전구체는, [(dmb2)Bi-O-Bi(dmb)2]2, 트리스(2,3-디메틸-2-부톡시) 비스무스(III), 트리스(삼차-부톡시) 비스무스(III), 트리(이소프로폭시) 비스무스(III), Bi(N(SiMe3)2)3, Bi(thd)3, Bi(OtBu)3, Bi(dmb)3, 및 Bi(CH2SiMe3)3로 이루어진 군으로부터 선택된 금속유기 비스무스 전구체를 포함하는, 방법.
  13. 삭제
  14. 제1항에 있어서, 상기 금속유기 전구체는, 트리메틸알루미늄(TMA), 트리메틸알루미늄(TEA), 디메틸알루미늄 클로라이드(AlMe2Cl), 디메틸알루미늄 이소프로폭시드(AlMe2OPr) 또는 알루미늄 에톡시드((AlOEt)3)로 이루어진 군으로부터 선택된 금속유기 알루미늄 전구체를 포함하는, 방법.
  15. 삭제
  16. 제1항에 있어서, 상기 금속유기 전구체는, 디메틸아연(ZnMe2), 디에틸아연(ZnEt2), 메틸아연 이소프로폭시드(ZnMe(OPr)), 또는 아연 아세테이트(Zn(CH)3CO2)2)로 이루어진 군으로부터 선택된 금속유기 아연 전구체를 포함하는, 방법.
  17. 삭제
  18. 삭제
  19. 제1항에 있어서, 상기 추가적인 유기 전구체는 일반 조성식 R3-CHO를 갖는 알데히드를 포함하며, 여기에서 R3는 수소, 및 선형 또는 분지형 C1 - C20 알킬 또는 알케닐기로 구성된 군으로부터 선택되는 것인, 방법.
  20. 제1항에 있어서, 상기 추가적인 유기 전구체는 알코올, 알데히드, 또는 카르복실 산 중 적어도 하나를 포함하는, 방법.
  21. 삭제
  22. 삭제
  23. 삭제
  24. 삭제
  25. 삭제
  26. 삭제
  27. 삭제
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