TW201448041A - 氮化鈦之選擇性移除 - Google Patents

氮化鈦之選擇性移除 Download PDF

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TW201448041A
TW201448041A TW103107465A TW103107465A TW201448041A TW 201448041 A TW201448041 A TW 201448041A TW 103107465 A TW103107465 A TW 103107465A TW 103107465 A TW103107465 A TW 103107465A TW 201448041 A TW201448041 A TW 201448041A
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plasma
region
titanium nitride
substrate
substrate processing
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Xikun Wang
An-Chuan Wang
Nitin K Ingle
Dmitry Lubomirsky
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Applied Materials Inc
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Abstract

本文中描述用於相對於介電質膜選擇性地蝕刻氮化鈦的方法，該介電質膜可以包括例如缺乏鈦的替代金屬和金屬氧化物及/或含矽膜(例如氧化矽、矽碳氮化物及低介電常數介電質膜)。該方法包括從含氯前驅物形成的遠端電漿蝕刻。使來自遠端電漿的電漿流出物流入基板處理區域，在該基板處理區域中電漿流出物與氮化鈦產生反應。電漿流出物與曝露的表面產生反應，並選擇性地去除氮化鈦，同時非常緩慢地去除其他曝露的材料。基板處理區域也可以含有電漿，以便於鑿穿任何存在於氮化鈦上的氧化鈦層。在基板處理區域中的電漿可以被和緩地相對於基板偏壓，以提高氧化鈦層的移除速率。

Description

氮化鈦之選擇性移除 【相關申請案的交叉引用】
本申請案主張於2013年6月3日提出申請的美國非臨時專利申請案第13/908,107號的優先權權益，第13/908,107號申請案主張於2013年3月5日提出申請的美國臨時專利申請案第61/772,658號的優先權權益，該二申請案之標題皆為「氮化鈦之選擇性移除(SELECTIVE TITANIUM NITRIDE REMOVAL)」，為了所有的目的將該二申請案全部以引用方式併入本文中。
本發明係關於半導體製程和設備。
藉由在基板表面上產生複雜圖案化材料層的製程使得積體電路成為可能。在基板上產生圖案化的材料需要受控制的、去除曝露材料的方法。化學蝕刻被使用於各種的目的，包括將光阻中的圖案轉移進入下面的層中、薄化各個層、或薄化已經存在表面上的特徵之側向尺寸。經常理想的是擁有蝕刻一種材料比另一種更快以有助於例如圖案轉移製程進行的蝕刻製程。這樣的蝕刻製程被稱為對第一種材料有選擇 性。由於材料、電路及製程多樣性的結果，已經開發出對各種材料具有選擇性的蝕刻製程。然而，使用乾蝕刻製程選擇性地蝕刻氮化鈦的選擇極少。
乾蝕刻製程對於選擇性地從半導體基板去除材料時常是理想的。該理想性源於和緩地從微型結構以最小的物理干擾去除材料的能力。乾蝕刻製程也允許藉由移除氣相試劑來突然終止蝕刻速度。某些乾蝕刻製程牽涉到使基板曝露於由一或更多種前驅物形成的遠端電漿副產物。例如，氨和三氟化氮的遠端電漿激發使氧化矽能夠在電漿流出物流入基板處理區域時被從圖案化基板選擇性地去除。最近遠端電漿蝕刻製程已被開發來相對於彼此選擇性地去除幾種介電質。然而，仍然需要乾蝕刻製程以各種新穎的製程流動精細地去除氮化鈦。
本文中描述用於相對於介電質膜選擇性地蝕刻氮化鈦的方法，該介電質膜可以包括例如缺乏鈦的替代金屬和金屬氧化物及/或含矽膜(例如氧化矽、矽碳氮化物及低介電常數介電質膜)。該方法包括從含氯前驅物形成的遠端電漿蝕刻。使來自遠端電漿的電漿流出物流入基板處理區域，在該基板處理區域中電漿流出物與氮化鈦產生反應。電漿流出物與曝露的表面產生反應，並選擇性地去除氮化鈦，同時非常緩慢地去除其他曝露的材料。基板處理區域也可以含有電漿，以便於鑿穿任何存在於氮化鈦上的氧化鈦層。在基板處理區域中的電漿可以被和緩地相對於基板偏壓，以提高氧化 鈦層的移除速率。
本發明的實施例包括在基板處理室的基板處理區域中蝕刻圖案化基板的方法。該圖案化基板具有曝露的氮化鈦區域和曝露的第二材料區域。該方法包括在該電漿區域中形成電漿的同時，使含氯前驅物流入與該基板處理區域流體耦接的遠端電漿區域，以產生電漿流出物。該方法進一步包括藉由使該電漿流出物通過噴灑頭中的通孔而流入該基板處理區域來從該基板蝕刻曝露的氮化鈦。
在以下的說明中部分提出另外的實施例與特徵，而且在檢視說明書之後，該等實施例與特徵之一部分對於熟悉該項技藝者而言將是顯而易見的，或者可以藉由實施所揭示的實施例來學習該等實施例與特徵之一部分。可以藉由說明書中所描述的儀器、組合及方法來實現和獲得所揭示實施例之特徵和優點。
110‧‧‧操作
120‧‧‧操作
125‧‧‧操作
130‧‧‧操作
133‧‧‧操作
135‧‧‧操作
145‧‧‧操作
1001‧‧‧基板處理室
1002‧‧‧遠端電漿系統
1003‧‧‧冷卻板材
1005‧‧‧入口組件
1010‧‧‧流體供應系統
1014‧‧‧上板
1015‧‧‧腔室電漿區域
1016‧‧‧下板
1017‧‧‧面板
1018‧‧‧空間
1019‧‧‧第一流體通道
1020‧‧‧絕緣環
1021‧‧‧第二流體通道
1023‧‧‧離子抑制器
1025‧‧‧噴灑頭
1027‧‧‧小孔
1031‧‧‧通孔
1033‧‧‧基板處理區域
1040‧‧‧電源
1055‧‧‧基板
1058‧‧‧氣體供應區域
1059‧‧‧孔
1065‧‧‧基座
1100‧‧‧處理系統
1102‧‧‧負載鎖定腔室
1104‧‧‧機器人手臂
1106‧‧‧保持區域
1108a-f‧‧‧基板處理室
1110‧‧‧第二機器人手臂
可以藉由參考剩餘部分的說明書和圖式來實現對所揭示實施例的本質和優點的進一步瞭解。
第1圖為依據所揭示實施例的氮化鈦選擇性蝕刻製程之流程圖。
第2A圖圖示依據所揭示技術的基板處理室之示意性剖視圖。
第2B圖圖示依據所揭示技術的一部分基板處理室之示意性剖視圖。
第2C圖圖示依據所揭示技術的噴灑頭之仰視圖。
第3圖圖示依據所揭示技術的示例性基板處理系統之俯視圖。
在附圖中，相似的元件及/或特徵可以具有相同的參考標號。另外，可以藉由在參考標號後面接續可區分相似元件的分號和第二標號來區分相同類型的各種元件。假使在說明書中只有使用第一參考標號，則此描述係適用於具有相同第一參考標號的類似元件中之任一者，並與第二參考標號無關。
本文中描述用於相對於介電質膜選擇性地蝕刻氮化鈦的方法，該介電質膜可以包括例如缺乏鈦的替代金屬和金屬氧化物及/或含矽膜(例如氧化矽、矽碳氮化物及低介電常數介電質膜)。該方法包括從含氯前驅物形成的遠端電漿蝕刻。使來自遠端電漿的電漿流出物流入基板處理區域，在該基板處理區域中電漿流出物與氮化鈦產生反應。電漿流出物與曝露的表面產生反應，並選擇性地去除氮化鈦，同時非常緩慢地去除其他曝露的材料。基板處理區域也可以含有電漿，以便於鑿穿任何存在於氮化鈦上的氧化鈦層。在基板處理區域中的電漿可以被和緩地相對於基板偏壓，以提高氧化鈦層的移除速率。
離子抑制元件可以被包括在本文所討論的蝕刻製程中，以實現高的氮化鈦選擇率。離子抑制元件的功能是減少或排除離子性帶電物種從電漿產生區域行進到基板上。不帶電的中性和自由基物種可以穿過離子抑制器中的開口，以在 基板進行反應。離子抑制器有助於將離子物種在反應區域中的濃度控制在可以協助該製程的水平。
依據本發明的一些實施例，在示例性的設備部分中描述的離子抑制器可被用以提供用於選擇性蝕刻基板的自由基及/或中性物種。離子抑制器被用來提供含氯電漿流出物，以選擇性地蝕刻氮化鈦。離子抑制器可被用以提供自由基濃度比離子更高的反應性氣體。因為電漿中大部分的帶電粒子會被離子抑制器過濾或去除，所以在蝕刻製程的過程中不一定需要對基板施加偏壓。這種使用自由基和其他中性物種的製程與傳統包括有效濺射和轟擊的電漿蝕刻製程相比可以減少電漿損傷。可以在該基板處理區域中包括局部電漿，以選擇性地提供濺射來從將被蝕刻的氮化鈦頂端去除(例如原生的)氧化鈦。可以相對於基板對局部電漿施加偏壓，以供應濺射組分到該蝕刻。局部電漿可以具有比遠端電漿更低的功率，在這種情況下，可以在氮化鈦的整個蝕刻中維持局部電漿而不影響氮化鈦的選擇性。本發明的實施例也優於傳統液體的表面張力會導致小的特徵彎曲和剝落的濕蝕刻製程。
為了更好地瞭解和理解本發明，現在參照第1圖，第1圖為依據揭示實施例的氮化鈦選擇性蝕刻製程之流程圖。由於曝露於大氣中，此實例的氮化鈦膜在其表面上具有薄的原生氧化物層。氮化鈦可以處於基板上毯覆層的形式，或是氮化鈦可以存在於圖案化基板表面的分離區域上。在任一情況下，一旦該原生氧化物層被移除，則氮化鈦可形成基板表面的曝露表面。然後基板被送入處理區域(操作110)。 在將基板送入處理區域之前，氧化鈦薄層可以存在或可以不存在於以其他方式曝露的基板氮化鈦區域上。
將氯(Cl2)的流動引入與處理區域分開的電漿區域(操作120)。可以使用其他來源的氯來增加或取代氯。一般來說，可以使含氯前驅物流入電漿區域，例如氯(Cl2)、二氯化氙或三氯化硼。分開的電漿區域在本文中可以被稱為遠端電漿區域，而且可以在與處理室不同的模組內或在處理室內的隔室內。還可以使含-碳-和-氫的前驅物(在這種情況下為甲烷(CH4))流入電漿區域(操作125)，其中該含-碳-和-氫的前驅物與氯在電漿中被同時激發。在流入含氯前驅物的操作過程中，使該含-碳-和-氫的前驅物流入電漿區域。該含-碳-和-氫的前驅物是選擇性的，並且主要被包括來幫助從氮化鈦的表面去除氧化鈦。
然後使在遠端電漿區域中形成的電漿流出物流入基板處理區域(操作130)。在這個實例中，而且時常在實施中，由於曝露於大氣的結果，原生氧化鈦層會存在於氮化鈦上面。藉由使電漿流出物流入基板處理區域來去除原生氧化鈦(操作133)。一旦原生氧化鈦被鑿穿，則基板上的氮化鈦即被選擇性地蝕刻(操作135)，使得若存在其他材料的話，氮化鈦可以比各種其他的材料更快速地被去除。在本文揭示的所有實例中所揭示的選擇性蝕刻可以蝕刻氮化鈦明顯快於蝕刻各種無鈦介電質材料，在本發明的實施例中，該無鈦介電質材料可以包括氧化鉿(HfO2)或含矽材料，該含矽材料例如矽(例如多晶矽)、氧化矽、低介電常數介電質、氮化矽或 矽碳氮化物。這樣的製程可以具有基礎廣泛的用途，例如，本文所揭示的蝕刻製程可被用於在圖案化之後從含矽膜堆疊的頂端選擇性地去除氮化鈦。從基板處理區域去除反應性化學物種和任何的製程流出物，然後從處理區域移出基板(操作145)。
一般來說，發明人已經發現氯或含氯前驅物能夠獲得氟基化學品無法獲得的選擇率。申請人假定包括氟必然提高含矽膜的去除速率，從而限制了對氮化鈦的蝕刻選擇率。申請人進一步假定氮化鈦與遠端電漿區域中產生的氯自由基相互作用而形成氯化鈦和氯化氮片段，從而與氟化鈦和氟化氮複合物相比具有高的蒸氣壓。另一方面，申請人發現，氯自由基去除氧化矽、低介電常數介電質、氮化矽、矽碳氮化物的速率遠比氮化鈦更慢。還觀察到鈦以外的金屬(以及該等金屬之氧化物)被蝕刻地非常緩慢，可能是由於該等金屬的氯-金屬化學片段具有低的蒸氣壓。
在本發明的實施例中，對於氮化鈦以外的材料來說，本文所揭示的製程之蝕刻選擇率(氮化鈦：氮化鈦以外的次要材料)可以大於或約為10：1、大於約為20：1、大於或約為50：1、或大於或約為100：1。本發明人已經發現，如不久後所陳述的，施加偏壓功率但保持低電平能夠實現非常高的選擇率。本發明人已經發現的是，本文所揭示的製程顯示相對於各種特定材料的氮化鈦蝕刻選擇率。在揭示的實施例中，氮化鈦相對於氮化矽的蝕刻選擇率可以大於或約為100：1、大於或約為250：1、大於或約為500：1、或大於或約為 1000：1。在實施中，在基板處理區域局部電漿中處於低偏壓功率的情況下，氮化矽和氧化矽的蝕刻速度是如此的低，以至於無法準確地量測。在本發明的實施例中，氮化鈦相對於氧化矽的蝕刻選擇率可以大於或約為100：1、大於或約為250：1、大於或約為500：1、或大於或約為1000：1。還發現低介電常數介電質薄膜，例如可向應用材料公司取得的Black Diamond IIITM基本上維持無法量測的蝕刻速度。在本發明的實施例中，氮化鈦相對於氧碳化矽(例如Black Diamond IIITM)的蝕刻選擇率可以大於或約為100：1、大於或約為250：1、大於或約為500：1、或大於或約為1000：1。觀察到矽碳氮化物(例如可向應用材料公司取得的BlokTM)具有低的蝕刻速度，但仍遠低於氮化鈦的蝕刻速度。在本發明的實施例中，氮化鈦相對於矽碳氮化物的蝕刻選擇率可以大於或約為5：1、大於或約為8：1、大於或約為12：1、或大於或約為15：1。
包括含-碳-和-氫的前驅物主要是為了協助從氮化鈦層的頂端去除氧化鈦層。在實例中該含-碳-和-氫的前驅物可以是甲烷(CH4)，但也可以是較高級的烴，例如乙烷(C2H6)。一般來說，該含-碳-和-氫的前驅物可以包括碳和氫，而且可以只由碳和氫所組成。在揭示的實施例中，該含-碳-和-氫的前驅物可以只含有單鍵。可以使用具有一些多鍵的烴，而且在製程過程中也可以將氫(H2)添加到遠端電漿區域，以調整H：C的原子流量比。
含氯前驅物和該含-碳-和-氫的前驅物的流動可以進一步包括一或更多種相對惰性的氣體，例如He、N2、Ar。惰 性氣體可被用來改善電漿穩定性、製程均勻性及類似者。氬氣作為添加劑是有幫助的，用以促進穩定的電漿形成。當包括氦氣時通常可以提高製程的均勻性。在整個說明書中這些添加劑存在於實施例中。可以使用不同氣體的流動速率和比例來控制蝕刻速度和蝕刻選擇率。
在揭示的實施例中，含氯前驅物(例如Cl2)被以約25sccm(標準立方公分/分鐘)和800sccm之間的流動速率供應，含-碳-和-氫的前驅物(例如CH4)被以約50sccm和600sccm之間的流動速率供應，He被以約0slm(標準升/分鐘)和3slm之間的流動速率供應，以及Ar被以約0slm和3slm之間的流動速率供應。本技術領域中具有通常知識者將認可的是，可以使用其他的氣體及/或流量，取決於許多的因素，包括處理室結構、基板的尺寸、幾何形狀及被蝕刻的特徵佈局及類似者。
該方法還包括將能量施加到在遠端電漿區域中的含氯前驅物和含-碳-和-氫的前驅物(CH4)，以產生電漿流出物。如本技術領域中具有通常知識者可以理解的，電漿可以包括數種帶電的和中性的物種，包括自由基和離子。可以使用習知的技術(例如射頻激發、電容耦合功率、感應耦合功率及類似者)來產生遠端電漿區域中(例如腔室電漿區域中)的電漿。在一實施例中，使用電容耦合電漿單元來施加能量。在本發明的實施例中，遠端電漿源功率可以在約40瓦和約1500瓦之間、約100瓦和約1200瓦之間、約250瓦和約1000瓦之間、或約400瓦和約800瓦之間。RF功率最窄的實施例 最佳化了氮化鈦相對於各種其他曝露材料的選擇性移除，該曝露材料包括含矽介電質膜以及一些不含鈦的金屬和金屬氧化物。在揭示的實施例中，遠端電漿區域中的壓力可以使得基板處理區域中的壓力最後在約0.01托和約20托之間或在約0.1托和約5托之間。電容耦合電漿單元可以被配置為遠離處理室的氣體反應區域(即基板處理區域)。例如，可以藉由噴灑頭將電容耦合電漿單元和電漿產生區域與氣體反應區域分隔。
在本文所述的蝕刻製程過程中也可以將電漿功率同時施加到遠端電漿區域(例如腔室電漿區域)和基板處理區域。腔室電漿區域中的電漿可以具有較高的施加功率，以形成進入基板處理區域的高濃度中性自由基。施加到基板處理區域的電漿功率可以比較低，以免不適當地提高基板附近的離子濃度。然而，可以相對於基板對基板處理區域中的局部電漿加偏壓，以施加濺射組分。包括局部電漿的濺射組分主要是可以去除可能覆蓋將被蝕刻的氮化鈦的氧化鈦。在本文中可以將基板處理區域中的電漿稱為本地局部電漿，因為該電漿的位置最接近基板並在基板處理區域內。可以使用與用以產生遠端電漿相同的技術來產生局部電漿。如同遠端電漿，在蝕刻過程中可以使用電容耦合電漿單元藉由在基板上方和下方的板材之間施加RF功率來施加能量。在本發明的實施例中，局部電漿的RF功率可以在約5瓦和約200瓦之間、約10瓦和約150瓦之間、約15瓦和約100瓦之間、或約20瓦特和約80瓦之間。基板處理區域中局部電漿的較低局部 RF功率保持低的離子濃度，所以朝向氮化鈦的蝕刻選擇率仍為高的。局部電漿的RF功率可以小於或約為20%的遠端電漿RF功率、小於或約為15%的遠端電漿RF功率、或小於或約為10%的遠端電漿RF功率。
在實施例中使用了局部電漿，以便於去除可能在氮化鈦層頂部上的氧化鈦層。可以相對於基板對局部電漿加偏壓，以除了化學機制之外藉由使用物理濺射機制來進一步協助去除任何的氧化鈦層。氧化鈦可能需要濺射的協助，因為氧化鈦中的鍵結比氮化鈦中的鍵結更強。在本發明的實施例中，局部電漿偏壓的RF功率可以在約2瓦和約100瓦之間、約3瓦和約75瓦之間、約5瓦和約60瓦之間、或約10瓦和約50瓦之間。局部電漿的RF功率不包括局部電漿偏壓的RF功率，所以施加的總RF功率為這兩個量的總和。
在蝕刻製程的過程中，一般來說可以將基板保持在約-30℃和約400℃之間。在實施例中，在本節所描述的乾蝕刻過程中基板的溫度可以大於或約為-30℃、大於或約為-10℃、大於或約為10℃、或大於或約為25℃。在揭示的實施例中，基板的溫度可以小於或約為400℃、小於或約為350℃、小於或約為250℃。在製程的過程中，基板處理區域可以被保持在等於或低於約20托、而且可以被保持在等於或低於約15托、5托、1托、0.1托等、或在約0.1毫托和約10托之間。
另外的製程參數係揭示於描述示例性處理室和系統的過程中。
示例性處理系統
第2A圖圖示示例性的基板處理室1001之剖面圖，基板處理室1001在處理室內具有隔開的電漿產生區域。在薄膜的蝕刻過程中，該薄膜例如氮化鈦、氮化鉭、鎢、矽、多晶矽、氧化矽、氮化矽、氧氮化矽或氧碳化矽等，可以使製程氣體經由氣體入口組件1105流入腔室電漿區域1015。遠端電漿系統(RPS)1002可以選擇性地被包括在該系統中，而且可以處理第一氣體，然後該第一氣體經由氣體入口組件1105前進。入口組件1105可以包括兩個或更多個不同的氣體供應通道，其中若包括的話第二通道(未圖示)可以繞過RPS 1002。因此，在揭示的實施例中，前驅物氣體可以以未被激發的狀態被輸送到處理室。在另一個實例中，通過RPS設置的第一通道可被用於製程氣體，而在揭示的實施例中繞過RPS的第二通道可被用於處理氣體。製程氣體可以在RPS 1002內被激發，然後進入腔室電漿區域1015。因此，在揭示的實施例中，如上所討論的含氯前驅物可以通過RPS 1002或繞過RPS單元。這種配置所涵蓋的各種其他實例將可同樣被理解。
依據揭示的實施例，冷卻板材1003、面板1017、離子抑制器1023、噴灑頭1025及上面放置基板1055的基板支座1065(亦習知為基座)被圖示出並且可以每個皆被包括。基座1065可以具有熱交換通道，熱交換流體流過該熱交換通道來控制基板的溫度。這個架構可以容許基板1055的溫度被冷卻或加熱來保持相對的低溫，例如介於約-20℃至約200℃之間。熱交換流體可以包含乙二醇及/或水。還可以使用嵌入的電阻加熱器元件來電阻式地加熱基座1065的晶圓支撐盤 (可以包含鋁、陶瓷或上述之組合)，以實現相對的高溫，例如從高達或約100℃至高於或約1100℃。加熱元件可以作為一或更多個迴圈被形成在基座內，並且加熱器元件的外部可以與支撐盤的周邊相鄰，而加熱器元件的內部係沿著具有較小半徑的同心圓路徑。接到加熱器元件的接線可以通過基座1065的底桿，基座1065的底桿可被進一步設置來旋轉。
面板1017可以是金字塔形、圓錐形或具有狹窄頂部擴展到寬底部的另一個類似結構。面板1017可以另外地如圖示為平坦的，並且包括複數個用於分配製程氣體的貫通通道。取決於RPS 1002的用途，電漿產生氣體及/或電漿激發物種可以通過面板1017中的複數個孔，如第2B圖所圖示，以更均勻地輸入腔室電漿區域1015。
示例性的架構可以包括使氣體入口組件1105對氣體供應區域1058開放，並藉由面板1017將氣體供應區域1058與腔室電漿區域1015分隔，使得氣體/物種流經面板1017中的孔進入腔室電漿區域1015。可以選擇結構和操作的特徵，以防止電漿從腔室電漿區域1015明顯回流返回進入供應區域1058、氣體入口組件1105及流體供應系統1010。結構特徵可以包括選擇面板1017中的孔之尺寸和橫截面幾何形狀，以使回流電漿失活。操作特徵可以包括保持氣體供應區域1058和腔室電漿區域1015之間的壓力差，該壓力差保持電漿單向流動通過噴灑頭1025。圖示面板1017(或腔室的導電頂部)和噴灑頭1025具有位於特徵之間的絕緣環1020，絕緣環1020允許AC電位被相對於噴灑頭1025及/或離子抑制器1023施 加到面板1017。絕緣環1020可以位於面板1017和噴灑頭1025及/或離子抑制器1023之間，以能夠在該第一電漿區域中形成電容耦合電漿(CCP)。擋板(未圖示)可以被另外放置在腔室電漿區域1015中或以其他方式與氣體入口組件1105耦接，以影響經由氣體入口組件1105進入該區域的流體流動。
離子抑制器1023可以包含板材或其他在整個結構中界定複數個孔的幾何形狀，該結構設以抑制離子化帶電物種遷移出腔室電漿區域1015，同時允許未帶電的中性或自由基物種通過離子抑制器1023進入該抑制器和噴灑頭之間的活化氣體輸送區域。在揭示的實施例中，離子抑制器1023可以包含具有各種孔架構的多孔板材。這些未帶電的物種可以包括高反應性的物種，該高反應性的物種被以較低反應性的載送氣體輸送通過該等孔。如以上所指出的，可以減少離子物種遷移通過該等孔，而且在一些情況下可以完全抑制離子物種遷移通過該等孔。控制離子物種通過離子抑制器1023的量可以對被帶入而與下方的晶圓基板接觸的氣體混合物提供增加的控制，進而可以增加對氣體混合物之沉積及/或蝕刻特性的控制。在進行沉積的替代實施例中，還可以對介電質材料平移保形對可流動類型沉積的平衡。
離子抑制器1023中的複數個孔可設以控制活性氣體通過離子抑制器1023，該活性氣體例如離子、自由基及/或中性物種。例如，可以控制孔的深寬比、或孔的直徑對長度及/或孔的幾何形狀，從而減少活化氣體中通過離子抑制器1023的離子化帶電物種的流量。離子抑制器1023中的孔可以 包括面向腔室電漿區域1015的錐形部分以及面向噴灑頭1025的圓柱形部分。可以設計圓柱形部分的形狀和尺寸來控制離子物種通到噴灑頭1025的流量。還可以施加可調整的電偏壓到離子抑制器1023作為控制通過抑制器的離子物種流量的另外手段。
離子抑制元件1023可以發揮減少或消除離子化帶電物種從電漿產生區域前進到基板的量的功能。未帶電的中性和自由基物種仍可以通過離子抑制器中的開口而與基板反應。應當指出的是，完全消除圍繞基板的反應區域中的離子化帶電物種並不總是所期望的目標。在許多的情況下，離子物種必須到達基板，以進行蝕刻及/或沉積製程。在這些情況下，離子抑制器可以有助於以協助製程的水平控制反應區域中的離子物種濃度。
噴灑頭1025與離子抑制器1023的組合可以允許電漿存在於腔室電漿區域1015中，以避免在基板處理區域1033中直接激發氣體，同時還允許激發的物種從腔室電漿區域1015進入基板處理區域1033。以這種方式中，腔室可設以防止電漿接觸被蝕刻的基板1055。這可以有利地保護若直接被產生的電漿接觸可能會被損壞、錯位或以其他方式變形的各種複雜結構和圖案化在基板上的薄膜。此外，當允許電漿接觸基板或接近基板的水平時，可以提高氧化物物種的蝕刻速度。因此，假使曝露的材料是氧化物，則可以藉由將電漿保持在基板的遠端來進一步保護這個材料。
該處理系統可以進一步包括與處理室電耦接的電源 1040，以提供電力給面板1017、離子抑制器1023、噴灑頭1025及/或基座1065，以在腔室電漿區域1015或處理區域1033中產生電漿。電源可設以視所進行的製程來輸送可調整的電力量至腔室。這樣的配置可允許可調整的電漿被用於所進行的製程。不像往往存在打開或關閉的功能的遠端電漿單元，可調整的電漿可設以輸送特定量的電力到腔室電漿區域1015。這接著可以允許發展出特定的電漿特性，使得前驅物可以被以特定的方式離解，以增強由這些前驅物生成的蝕刻輪廓。
電漿可以在噴灑頭1025上方的腔室電漿區域1015中及/或噴灑頭1025下方的基板處理區域1033中被點燃。電漿可以存在腔室電漿區域1015中，以從含氯前驅物的進入流產生自由基-氯前驅物。可以在處理室的導電性頂部(例如面板1017)和噴灑頭1025及/或離子抑制器1023之間施加通常在射頻(RF)範圍中的交流電壓，以在沉積過程中在腔室電漿區域1015中點燃電漿。RF電源可以產生13.56MHz的高射頻頻率，但也可能會產生其他單獨的或與13.56MHz頻率結合的頻率。
電漿功率可以有各種的頻率或多種頻率的組合。在示例性的處理系統中，電漿可以由被相對於離子抑制器1023及/或噴灑頭1025輸送到面板1017的RF功率提供。在不同的實施例中，RF功率可以在約10瓦和約2000瓦之間、約100瓦和約2000瓦之間、約200瓦和約1500瓦之間或約200瓦和約1000瓦之間。在不同的實施例中，該示例性的處理系統中施加的RF頻率可以是小於約200kHz的低RF頻率、在約 10MHz和約15MHz之間的高RF頻率或大於或約1GHz的微波頻率。電漿功率可以被電容耦合或感應耦合進入遠端電漿區域。
在本文所述的蝕刻製程過程中，還可以同時將電漿功率施加到腔室電漿區域1015和基板處理區域1033。上述的頻率和功率皆適用於這兩個區域。任一區域皆可使用電容耦合電漿(CCP)或感應耦合電漿(ICP)進行激發。腔室電漿區域1015中的電漿可以具有較高的施加功率，以形成進入基板處理區域1033的高濃度中性自由基。施加到基板處理區域1033的電漿功率可以較低，以免不適當地增加基板附近的離子濃度。然而，可以相對於基板對基板處理區域1033中的電漿加偏壓，以施加濺射組分來去除可能覆蓋將被蝕刻的氮化鈦的氧化鈦。
當開啟基板處理區域1033中的底部電漿以例如固化薄膜或清洗鄰接基板處理區域1033的內表面時，可以使腔室電漿區域1015(圖式中的頂部電漿)停留在很低或無功率下。可以藉由在噴灑頭1055和基座1065或腔室底部之間施加交流電壓來點燃基板處理區域1033中的電漿。可以在電漿存在的同時將清洗氣體引入基板處理區域1033。
可以藉由本文所述的噴灑頭之實施例使流體(諸如前驅物，例如含氯前驅物)流入處理區域1033。在腔室電漿區域1015中從製程氣體衍生的激發物種可以行進通過離子抑制器1023中的孔及/或噴灑頭1025，並與另外從噴灑頭的獨立部分流入處理區域1033的前驅物反應。或者，假使所有的 前驅物物種都是在腔室電漿區域1015中被激發，則沒有另外的前驅物可以流過噴灑頭的該獨立部分。極少或沒有電漿可以存在於處理區域1033中。在揭示的申請案中，前驅物的激發衍生物可以在基板上方的區域中結合，並且偶爾在基板上結合，以在基板上蝕刻結構或去除物種。
直接在腔室電漿區域1015中激發流體或在RPS單元1002中激發流體可以提供幾個效益。由於腔室電漿區域1015中的電漿，可以增加處理區域1033內衍生自流體的激發物種之濃度。這種增加可能是由於電漿在腔室電漿區域1015中的位置所致。處理區域1033可以位於比遠端電漿系統(RPS)1002更靠近腔室電漿區域1015，故留下較少的時間讓激發物種經由與其他氣體分子、腔室壁及噴灑頭的表面碰撞而離開激發態。
還可以提高處理區域1033內衍生自製程氣體的激發物種的濃度之均勻性。這可以得自腔室電漿區域1015的形狀，腔室電漿區域1015的形狀可以更類似於處理區域1033的形狀。在RPS 1002中產生的激發物種相對於通過靠近噴灑頭1025中心的孔的物種可以行進更遠的距離，以通過鄰近噴灑頭1025邊緣的孔。較大的距離可能會導致激發物種的激發減少，而且例如可能會導致靠近基板邊緣的生長速率較緩慢。在第一電漿區域1015中激發流體可以減少流過RPS 1002或者是繞過RPS單元周圍的流體的這種變化。
處理氣體可以在腔室電漿區域1015中被激發，而且可以以激發態通過噴灑頭1025到達處理區1033。雖然可以在 處理區域1033中產生電漿，但也可以替代地不在處理區域中產生電漿。在一個實例中，處理氣體或前驅物的唯一激發可以是來自在腔室電漿區域1015中激發處理氣體，以與在處理區域1033中的他者反應。如前面所討論的，這可以是為了保護圖案化於基板1055上的結構。
除了流體前驅物之外，可以為了不同的目的在不同的時間引導其他的氣體，包括載送氣體，以幫助輸送。在沉積過程中，可以引導處理氣體來從腔室壁、基板、沉積薄膜及/或薄膜去除不要的物種。可以在電漿中激發處理氣體，然後使用該處理氣體來減少或去除腔室內殘留的內容物。在其他所揭示的實施例中，也可以使用沒有電漿的處理氣體。當處理氣體包括水蒸汽時，可以使用質量流量計(MFM)、噴射閥或由市售的水蒸汽產生器來實現輸送。可以經由RPS單元或繞過RPS單元將處理氣體引到處理區域1033，而且可以進一步在第一電漿區域中激發處理氣體。
第2B圖圖示藉由面板1017影響處理氣體分佈的特徵之詳細視圖。如第2A圖和第2B圖中所圖示，面板1017、冷卻板1003及氣體入口組件1105相交以界定出氣體供應區域1058，製程氣體可以從氣體入口1105被輸入氣體供應區域1058。氣體可以填滿氣體供應區域1058並通過面板1017中的孔1059流到第一電漿區域1015。孔1059可設以以大致上單向的方式來引導流動，使得製程氣體可以流入處理區域1033，但是也可以在穿過面板1017之後被部分地或完全地防止回流進入氣體供應區域1058。
可以將用於處理室部分1001的氣體分配組件(例如噴灑頭1025)稱為雙通道噴灑頭(DCSH)並另外詳述於本文中的第2A圖及第2C圖所描述的實施例中。該雙通道噴灑頭可以準備用於蝕刻製程，該蝕刻製程允許在處理區域1033外部分離蝕刻劑，以在被輸入處理區域之前提供有限的、與腔室元件和彼此的交互作用。
噴灑頭1025可以包含上板1014和下板1016。該等板可以彼此耦接，以界定該等板之間的空間1018。該等板的耦接可以便於提供通過上板和下板的第一流體通道1019及通過下板1016的第二流體通道1021。所形成的通道可設以單獨經由第二流體通道1021來提供從空間1018通過下板1016的流體進出，並且可以將第一流體通道1019與該等板之間的空間1018和第二流體通道1021流體隔離。可以經由氣體分配組件1025的一側流體進出空間1018。雖然第2圖的示例性系統包括雙通道噴灑頭，但應當理解的是，可以使用替代的分配組件來在到達處理區域1033之前將第一和第二前驅物保持流體隔離。例如，可以使用多孔板和板下面的管，雖然其他的配置也可以以降低的效率進行操作或無法提供如同所述雙通道噴灑頭一樣均勻的處理。
在圖示的實施例中，噴灑頭1025可以經由第一流體通道1019分配製程氣體，在腔室電漿區域1015中被電漿激發之後該製程氣體含有電漿流出物。在實施例中，被引入RPS 1002及/或腔室電漿區域1015的製程氣體可以含有氯，例如Cl2或BCl3及類似者。該製程氣體還可以包括載送氣體，例如 氦氣、氬氣、氮氣(N2)等。電漿流出物可以包括製程氣體的離子化或中性衍生物，而且本文中還可以將電漿流出物稱為自由基-氯前驅物，以指稱引入的製程氣體之原子組分。
第2C圖為依據揭示的實施例用於處理室的噴灑頭1025之仰視圖。噴灑頭1025與第2A圖中圖示的噴灑頭一致。圖示第一流體通道1019的一個視圖的通孔1031可以具有複數種形狀和架構，以控制並影響通過噴灑頭1025的前驅物流動。圖示第二流體通道1021的一個視圖的小孔1027可以大致上均勻地分佈在噴灑頭的表面上，即使在通孔1031之間亦然，此可有助於在前驅物離開噴灑頭時提供比其他架構更為均勻的前驅物混合。
另外的雙通道噴灑頭以及此處理系統和腔室在2011年10月3日提出申請的專利申請案序號第13/251,714號中有更完整的描述，為了所有的目的將該專利申請案以引用方式併入本文中，惟併入程度係不與本文中所主張的特徵和說明不一致。
可以將腔室電漿區域1015或遠端電漿系統中的區域稱為遠端電漿區域。在實施例中，自由基前驅物，例如自由基-氯前驅物係形成於遠端電漿區域中並進入基板處理區域。在實施例中，可以或可以不將電漿功率僅施加於遠端電漿區域，取決於是否需要將氧化鈦層鑿穿來接近氮化鈦層。在揭示的實施例中，可以使氯或另一種含氯前驅物以約25sccm和約500sccm之間、約50sccm和約150sccm之間或約75sccm和約125sccm之間的速率流入腔室電漿區域1015。 可以使甲烷或另一種烴流入。
進入腔室的前驅物之結合流動速率以體積計可以佔整體氣體混合物的0.05%至約20%；其餘的是載送氣體。在實施例中可以使含氯前驅物流入遠端電漿區域，但電漿流出物可以具有相同的體積流量比。在含氯前驅物的情況下，可以在含氯氣體之前先使淨化或載送氣體進入遠端電漿區域，以穩定遠端電漿區域內的壓力。
在前驅物、任何載送氣體和電漿流出物流入基板處理區域1033的過程中，可以將基板處理區域1033保持在各種壓力下。在不同的實施例中，可以將該壓力保持在約0.1毫托和約20托之間或約1托和約5托之間。
可以將沉積系統的實施例結合到更大的製造系統中，以生產積體電路晶片。第3圖圖示依據所揭示實施例的沉積、蝕刻、烘烤及固化腔室的一個這種處理系統1101。在該圖中，一對前開式晶圓傳送盒(負載鎖定腔室1102)供應各種尺寸的基板，該等基板由機器人手臂1104接收，並在被放入其中一個基板處理室1108 a-f之前被放入低壓保持區域1106。可以使用第二機器人手臂1110來在保持區域1106和基板處理室1108a-f之間來回運送基板晶圓。可以整體配備每個基板處理室1108a-f，以進行數種基板處理操作，除了循環層沉積(CLD)、原子層沉積(ALD)、化學氣相沉積(CVD)、物理氣相沉積(PVD)、蝕刻、預清洗、除氣、定向及其他的基板製程之外，該基板處理操作還包括本文所述的乾蝕刻製程。
基板處理室1108a-f可以包括一或更多個系統元件，用於沉積、退火、固化及/或蝕刻基板晶圓上的介電質薄膜。在一個架構中，可以使用兩對處理室(例如1108c-d和1108e-f)來在基板上沉積介電質材料，並且可以使用第三對處理室(例如1108a-b)來蝕刻沉積的介電質。在另一個架構中，可以將全部的三對腔室(例如1108a-f)配置為蝕刻基板上的介電質薄膜。可以在與不同的實施例中所圖示的製造系統分離的腔室中進行所描述的任一種或更多種製程。
在前面的描述中，為了說明的目的，已經闡述許多的細節，以提供對本發明之各種實施例的瞭解。然而，對於本技術領域中具有通常知識者而言，顯而易見的是，可以不使用這些細節中的一些、或是使用其他的細節來實施某些實施例。
本文中所使用的「基板」可以是具有或不具有形成在其上的層的支撐基板。圖案化的基板可以是絕緣體或具有多種摻雜濃度和分佈的半導體，而且可以例如是用於積體電路製造的類型的半導體基板。圖案化基板之曝露的「矽」主要是Si，但也可以包括少數濃度的其它元素組分，例如氮、氧、氫、碳及類似者。圖案化基板之曝露的「氮化鈦」主要是鈦和氮，但也可以包括少數濃度的其它元素組分，例如氧、氫、碳及類似者。當然，「曝露的氮化鈦」可以只由鈦和氮所組成。圖案化基板之曝露的「氮化矽」主要是Si3N4，但也可以包括少數濃度的其它元素組分，例如氧、氫、碳及類似者。「曝露的氮化矽」可以只由矽和氮所組成。圖案化基板之曝 露的「氧化矽」主要是SiO2，但也可以包括少數濃度的其它元素組分，例如氮、氫、碳及類似者。在一些實施例中，使用本文揭示的方法蝕刻的氧化矽膜係由矽和氧所組成。「氧化鈦」主要是鈦和氧，但也可以包括少數濃度的其它元素組分，例如氮、氫、碳及類似者。氧化鈦可以由鈦和氧所組成。
術語「前驅物」係用以指稱任何參與反應以從表面去除材料或沉積材料到表面上的製程氣體。「電漿流出物」形容從腔室電漿區域離開並進入基板處理區域的氣體。電漿流出物係處在「激發態」，其中至少一些氣體分子係處於振動激發、解離及/或離子化的狀態。「自由基前驅物」係用以描述參與反應以從表面去除材料或沉積材料到表面上的電漿流出物(處於激發狀態並從電漿排出的氣體)。「自由基-氯」是含有氯但也可以含有其他元素組分的自由基前驅物。片語「惰性氣體」係指任何在蝕刻或被摻入膜中時不形成化學鍵的氣體。示例性的惰性氣體包括稀有氣體，但也可以包括其他的氣體，只要當(典型地)微量陷入膜中時沒有化學鍵形成即可。
術語「縫隙」和「溝槽」被用於全文，但並非暗示蝕刻出的幾何形狀具有大的水平深寬比。從表面上方觀看時，溝槽可能顯現出圓形、橢圓形、多邊形、矩形或各種其他的形狀。溝槽可以處於圍繞島狀材料的護城河形狀。術語「通孔」係用以指稱低深寬比的溝槽(從上方觀看)，該低深寬比的溝槽可以或可以不被填充金屬而形成垂直的電連接。如本文中所使用的，保形的蝕刻處理係指大致均勻地去除表 面上的材料而產生與表面相同的形狀，亦即，被蝕刻層的表面和蝕刻前的表面是大致上平行的。本技術領域中具有通常知識之人士將認可的是，被蝕刻的界面很可能無法是100%保形的，因此術語「大致上」允許可接受的公差。
有了揭示的幾個實施例，在本技術領域中具有通常知識者將理解到，可以在不偏離本發明之精神下使用各種修改、替代結構以及均等物。此外，並未描述數個習知的製程及元件，以避免不必要地混淆本發明。因此，不應將以上描述視為限制本發明之範圍。
當提供數值的範圍時，應瞭解到，除非內文以其他方式清楚指明，否則在該範圍的上限與下限之間、每個到下限單位的十分之一之中間值亦為具體揭示的。在陳述範圍中的任何陳述值或中間值與該陳述範圍中的任何其他陳述值或中間值之間的每個較小範圍亦被涵括。該等較小範圍的上限與下限可獨立地被包括或排除於該範圍中，而且不論是該等較小範圍包括任一限值、不包括二限值或是包括二限值，該等較小範圍中的每個範圍亦被涵括於本發明中，取決於該陳述範圍中任何經具體排除的限值。當該陳述範圍包括該等限值中之一者或二者時，排除該等包括的限值中之任一者或二者的範圍亦被包括。
除非內文以其他方式清楚指明，否則本文中與所附申請專利範圍中使用的單數形「一」及「該」包括複數的指示對象。因此，舉例來說，提及「一製程」係包括複數個該種製程，而提及「該介電質材料」係包括提及一或更多種介 電質材料及其為本技術領域中具有通常知識者所習知的均等物，以此類推。
同樣地，當用於本說明書中及以下申請專利範圍中時，字眼「包含」及「包括」意欲指明陳述的特徵、整數、元件或步驟之存在，但該等字眼並不排除一或更多個其他的特徵、整數、元件、步驟、動作或基團的存在或加入。
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Claims (18)

  1. 一種在一基板處理室的一基板處理區域中蝕刻一圖案化基板的方法，其中該圖案化基板具有一曝露的氮化鈦區域和一曝露的第二材料區域，該方法包含以下步驟：在該遠端電漿區域中使用一遠端RF功率形成一遠端電漿的同時，使一含氯前驅物流入一與該基板處理區域流體耦接的遠端電漿區域，以產生電漿流出物；以及藉由使該電漿流出物通過一噴灑頭中的通孔而流入該基板處理區域來從該基板蝕刻曝露的氮化鈦。
  2. 如請求項1所述之方法，其中在該蝕刻操作之前該曝露的氮化鈦區域被一氧化鈦層覆蓋，其中藉由使該電漿流出物流入該基板處理區域來去除該氧化鈦層，以在蝕刻該曝露的氮化鈦的操作之前形成該曝露的氮化鈦區域。
  3. 如請求項1所述之方法，其中該曝露的氮化鈦區域係由鈦和氮所組成。
  4. 如請求項1所述之方法，進一步包含在流入該含氯前驅物的操作過程中使一含-碳-和-氫的前驅物流入該遠端電漿區域。
  5. 如請求項4所述之方法，其中該含-碳-和-氫的前驅物包含甲烷。
  6. 如請求項4所述之方法，其中該含-碳-和-氫的前驅物係由碳和氫所組成。
  7. 如請求項1所述之方法，其中蝕刻該曝露的氮化鈦區域包含使用一比該曝露的第二材料區域的蝕刻速度大十倍的氮化鈦蝕刻速度蝕刻氮化鈦。
  8. 如請求項1所述之方法，其中蝕刻氮化鈦的操作包含以比氮化矽快約100：1或更大的比率、比氧化矽快約100：1或更大的比率、比矽碳氮化物快約5：1或更大的比率、或比氧碳化矽快約100：1或更大的比率蝕刻氮化鈦。
  9. 如請求項1所述之方法，其中該含氯前驅物包含氯和三氯化硼中之至少一者。
  10. 如請求項1所述之方法，其中在該蝕刻操作的過程中，該基板處理區域內的一壓力係在約0.01托和約20托之間。
  11. 如請求項1所述之方法，其中在該遠端電漿區域中形成一遠端電漿以產生電漿流出物包含施加一在約40瓦和約1500瓦之間的遠端RF功率到該電漿區域。
  12. 如請求項1所述之方法，進一步包含在該電漿區域中形 成該遠端電漿的操作過程中，在該基板處理區域中形成一局部電漿。
  13. 如請求項12所述之方法，其中在該基板處理區域中形成該局部電漿包含施加一在約5瓦和約200瓦之間的局部電漿RF功率到該電漿區域。
  14. 如請求項12所述之方法，其中形成該局部電漿包含施加一局部電漿RF功率，該局部電漿RF功率為該遠端RF功率之約20%或小於該遠端RF功率。
  15. 如請求項12所述之方法，其中在該基板處理區域中形成該局部電漿包含在該電漿和該圖案化基板之間施加一局部電漿偏壓RF功率。
  16. 如請求項15所述之方法，其中該局部電漿偏壓RF功率係介於約2瓦和約100瓦之間。
  17. 如請求項1所述之方法，其中在該蝕刻操作過程中該基板之一處理溫度係大於或約為一30℃並小於或約為400℃。
  18. 一種基板處理系統，包含：一具有一內部體積的處理室，該內部體積能夠與一外部腔室壓力保持一內部腔室壓力差； 一隔板，該隔板將該處理室的該內部體積分成一第一電漿區域和一第二電漿區域，其中該處理室設以允許在每個該第一和第二電漿區域中形成可獨立操作的電漿；一製程氣體通道，設以從該處理室外部輸送一製程氣體進入該第一電漿區域；一基板基座，位於該第二電漿區域內；複數個孔，在該隔板中，以允許氣體從該第一電漿區域通到該第二電漿區域，其中該第一電漿區域設以容納一第一電漿並且該第二電漿區域設以容納一第二電漿，其中該第二電漿區域設以施加一來源電漿功率及一偏壓電漿功率，以加速離子前往該基板基座；以及一離子抑制器，鄰近該隔板並位於該第一電漿區域中。
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