TWI707969B - 用於含金屬材料的高壓退火過程 - Google Patents

用於含金屬材料的高壓退火過程 Download PDF

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TWI707969B
TWI707969B TW108104585A TW108104585A TWI707969B TW I707969 B TWI707969 B TW I707969B TW 108104585 A TW108104585 A TW 108104585A TW 108104585 A TW108104585 A TW 108104585A TW I707969 B TWI707969 B TW I707969B
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卡沙爾K 辛格
美伊 雪克
史林尼法斯D 奈馬尼
怡利 葉
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美商應用材料股份有限公司
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Abstract

本揭示內容提供了用於在TFT顯示應用、半導體、或記憶體應用中在含金屬層上執行退火過程的方法。在一個實例中,一種在基板上形成含金屬層的方法包括以下步驟:在處理腔室中的基板上供應含氧氣體混合物,該基板包括設置在光學透明基板上的含金屬層;將該處理腔室中的該含氧氣體混合物維持在約2巴到約50巴之間的過程壓力下;及在該含氧氣體混合物存在的情況下熱退火該含金屬層。

Description

用於含金屬材料的高壓退火過程
本發明的實施例大致與用於在可以利用在TFT設備結構、半導體、或記憶體應用中的膜堆疊中形成含金屬層的方法相關。
顯示設備已經被廣泛地用於範圍廣泛的電子應用,例如TV、監視器、手機、MP3播放器、電子書閱讀器、及個人數位助理(PDA)等等。顯示設備一般被設計為用於藉由向液晶施加電場來產生所需的影像,該液晶填充兩個基板之間的間隙且具有控制介電場強度的各向異性的介電常數。藉由調整透射通過基板的光的量,可以高效地控制光及影像的強度、品質、及功率消耗。
可以將各種不同的顯示設備(例如有源矩陣液晶顯示器(AMLCD)或有源矩陣有機發光二極體(AMOLED))採用為利用觸控螢幕面板的顯示設備的光源。在製造TFT設備時,具有高電子遷移率、低洩漏電流、及高擊穿電壓的電子設備會允許更多像素面積用於光透射及電路系統的整合,因此造成更亮的顯像、更高的整體電效率、更快速的響應時間、及更高解析度的顯像。形成於設備中的低膜品質的材料層(例如具有雜質的金屬電極層)通常造成了不良的設備電氣效能及短的設備使用壽命。因此,對於提供具有低的膜洩漏的設備結構,用於在TFT設備中形成膜層及將膜層與TFT設備整合在一起的穩定及可靠的方法變得至關重要,且需要高的擊穿電壓以供用於製造具有較低臨限電壓偏移的電子設備及改善電子設備的整體效能。
因此,需要改善的材料以用於製造產生改善的設備電氣效能及設備穩定性的TFT設備。
本揭示內容提供了用於在TFT顯示應用、半導體、或電阻式隨機存取記憶體(ReRAM)中在含金屬層上執行退火過程的方法。在一個實例中,一種在基板上形成含金屬層的方法包括以下步驟:在處理腔室中的基板上供應含氧氣體混合物,該基板包括設置在光學透明基板上的含金屬層;將該處理腔室中的該含氧氣體混合物維持在2巴到50巴之間的過程壓力下;及在該含氧氣體混合物存在的情況下熱退火該含金屬層。
在另一個實例中,一種用於緻密化設置在基板上的含金屬層的方法包括以下步驟:在大於2巴的壓力下熱處理設置在光學透明基板上的含金屬層;及在熱處理介電層的期間將基板溫度維持小於攝氏500度。
在又另一個實例中,一種用於緻密化設置在基板上的含金屬層的方法包括以下步驟:在基板上形成含金屬層;將摻雜物植入到該含金屬層中;及在大於2巴的壓力下熱處理該基板上的該含金屬層,同時將基板溫度維持小於攝氏500度。
本揭示內容的實施例大致提供了一種TFT設備結構及在該TFT設備結構中的源極、汲極、介面、及接觸區域的有源層上執行熱退火過程以便增強顯示設備的電氣效能的方法。其他的應用(包括半導體或記憶體設備製造過程)也可以利用本文中所述的實施例。熱退火過程可以緻密化基板上的金屬電極、源極/汲極及/或接觸區域、及/或膜層的有源層膜性質。在一個實例中,熱處理過程被執行以提供含金屬層的熱能,例如含金屬層(例如有源層)或金屬電極層(例如金屬閘極電極、源極-汲極及/或接觸區域或電極層、或其他合適的金屬結構)形成於TFT設備中。熱退火過程可以緻密化或最小化有源層膜結構中的氧缺乏,以向設備結構提供良好的品質、介面管理、及熱穩定。熱退火過程也可以增加含金屬材料的結晶度,而改善含金屬層的電氣效能。因此,顯示設備中的源極/汲極及/或接觸區域的金屬電極及有源層所需的膜性質可以高效地增強電晶體及二極體設備的電氣效能。
圖1是用於單個基板的高壓退火過程的單基板處理腔室100的簡化正橫截面圖。單基板處理腔室100具有主體110,該主體具有包封內部容積115的外表面112及內表面113。在例如圖1中的一些實施例中,主體110具有環狀橫截面,然而在其他的實施例中,主體110的橫截面可以是矩形或任何封閉的形狀。可以由抗腐蝕鋼(CRS)(例如但不限於不銹鋼)製作主體110的外表面112。一或更多個隔熱罩125被設置在主體110的內表面113上,該隔熱罩防止來自單基板處理腔室100的熱損失進入外部環境。可以由鎳基鋼合金製作主體110的內表面113以及隔熱罩125,該等鎳基鋼合金展現高度的腐蝕抗性,例如但不限於HASTELLOY® 、ICONEL® 、及MONEL®
基板支撐物130被設置在內部容積115內。基板支撐物130具有桿134及由桿134所固持的基板支撐構件132。桿134穿過形成通過腔室主體110的通路122。連接到致動器138的桿139穿過形成通過腔室主體110的第二通路123。桿139被耦接到具有孔136的板135,該孔容納基板支撐物130的桿134。升降銷137被連接到基板支撐構件132。致動器138致動桿139,使得板135上下移動以與升降銷137連接及斷接。隨著升降銷137升高或降低,基板支撐構件132在腔室100的內部容積115內升高或降低。基板支撐構件132具有嵌入在中心內的電阻式加熱元件131。電源133被配置為向電阻式加熱元件131供電。電源133以及致動器138的操作被控制器180控制。
單基板處理腔室100在主體110上具有開口111,通過該開口,可以向及從設置在內部容積115中的基板支撐物130裝載及卸載一或更多個基板120。開口111在主體110上形成隧道121。縫閥128被配置為可密封地封閉隧道121,使得只有在縫閥128開啟時才能夠進出開口111及內部容積115。高壓密封件127被用來將縫閥128密封到主體110,以密封內部容積115以供進行處理。可以由聚合物製作高壓密封件127,例如含氟聚合物,例如但不限於全氟彈性體及聚四氟乙烯(PTFE)。高壓密封件127可以更包括彈簧構件以供偏壓密封件以改善密封效能。冷卻通道124被設置在隧道121上在高壓密封件127附近,以在處理期間將高壓密封件127維持低於高壓密封件127的最大安全操作溫度。可以將來自冷卻流體源126的冷卻劑(例如但不限於惰性、介電、及高效能導熱流體)在冷卻通道124內循環。來自冷卻流體源126的冷卻劑的流量是藉由控制器180通過從溫度感測器116或流量感測器(未示出)所接收的反饋來控制的。環狀熱扼流圈129圍繞隧道221而形成以防止來自內部容積115的熱在縫閥128開啟時流過開口111。
單基板處理腔室100具有通過主體110的端口117,該端口被流體連接到流體迴路190,該流體迴路連接氣體面板150、冷凝器160、及端口117。流體迴路190具有導氣管192、來源導管157、入口隔離閥155、排氣導管163、及出口隔離閥165。許多加熱器196、158、152、154、164、166與流體迴路190的不同部分交接。許多溫度感測器151、153、119、167、及169也被安置在流體迴路190的不同部分處,以截取溫度量度及向控制器180發送資訊。控制器180使用溫度測量資訊來控制加熱器152、154、158、196、164、及166的操作,使得流體迴路190的溫度被維持在高於設置在流體迴路190及內部容積115中的處理流體的冷凝點的溫度。
氣體面板150被配置為在內部容積115的壓力之下提供處理流體。引入到內部容積115中的處理流體的壓力被耦接到主體110的壓力感測器114監測。冷凝器160被流體耦接到冷卻流體源(未示出)且被配置為冷凝通過導氣管192離開內部容積115的氣相處理流體。冷凝的處理流體接著被泵176移除。一或更多個加熱器140被設置在主體110上且被配置為加熱單基板處理腔室100內的內部容積115。加熱器140、152、154、158、196、164、及166在通往冷凝器160的出口隔離閥165開啟的同時將流體迴路190內的處理流體維持在氣相下,以防止流體迴路內的冷凝。
控制器180控制單基板處理腔室100的操作。控制器180控制氣體面板150、冷凝器160、泵170、入口隔離閥155、出口隔離閥165、電源133及145的操作。控制器180也被通訊連接到溫度感測器116、壓力感測器114、致動器138、冷卻流體源126、及溫度讀數設備156及162。
處理流體可以包括含氧的及/或含氮的氣體、及/或硫族或碲(例如S、Se、Te)氣體或蒸氣,例如氧氣、乾蒸汽、水、過氧化氫、氨、S蒸氣、Se蒸氣、H2 S、H2 Se等等。處理流體可以與基板上的金屬材料起反應以形成金屬氮氧化物、金屬氧化物、金屬氧硫族元素化物、或金屬硫族化物。替代於或附加於含氧的及/或含氮的氣體,處理流體可以包括含矽氣體。含矽氣體的實例包括有機矽、正矽酸四烷基酯氣體及二矽氧烷。有機矽氣體包括具有至少一種碳-矽鍵的有機化合物的氣體。正矽酸四烷基酯氣體包括由附接到SiO4 4 離子的四個烷基組成的氣體。更特定而言,該一或更多種氣體可以是(二甲基甲矽烷基)(三甲基甲矽烷基)甲烷((Me)3 SiCH2 SiH(Me)2 )、六甲基二矽烷((Me)3 SiSi(Me)3 )、三甲基矽烷((Me)3 SiH)、三甲基甲矽烷基氯((Me)3 SiCl)、四甲基矽烷((Me)4 Si)、四乙氧基矽烷((EtO)4 Si)、四甲氧基矽烷((MeO)4 Si)、四(三甲基甲矽烷基)矽烷((Me3 Si)4 Si)、(二甲基胺基)二甲基矽烷((Me2 N)SiHMe2 )、二甲基二乙氧基矽烷((EtO)2 Si(Me)2 )、二甲基二甲氧基矽烷((MeO)2 Si(Me)2 )、甲基三甲氧基矽烷((MeO)3 Si(Me))、二甲氧基四甲基二矽氧烷(((Me)2 Si(OMe))2 O)、三(二甲基胺基)矽烷((Me2 N)3 SiH)、雙(二甲基胺基)甲基矽烷((Me2 N)2 CH3 SiH)、二矽氧烷((SiH3 )2 O)、及上述項目的組合。
在基板120的處理期間,高壓區域115的環境被維持在將高壓區域內的處理流體維持在氣相的溫度及壓力下。此類壓力及溫度是基於處理流體的組成來選定的。在蒸氣的情況下,溫度及壓力被保持在將蒸氣維持在乾蒸氣狀態的條件下。在一個實例中,高壓區域115被加壓到大於大氣的壓力,例如大於約2巴。在另一個實例中,高壓區域115被加壓到從約10到約50巴(例如從約20到約50巴之間)的壓力。在另一個實例中,高壓區域115被加壓到高達100巴的壓力。在處理期間,高壓區域115也被維持在高溫下,例如超過攝氏225度的溫度(由設置在輸送盒150上的基板155的熱預算所限制),例如在約攝氏300度到約攝氏500度之間。
圖2是示例性處理系統200的示意俯視平面圖,該處理系統包括併入及整合在該處理系統中的處理腔室(例如圖1中所繪示的處理腔室100)中的一或更多者。在一個實施例中,處理系統200可以是可從位於加州聖克拉拉市的應用材料公司購得的Centura® 或Endura® 集成處理系統。預期的是,可以將其他的處理系統(包括來自其他製造商的彼等處理系統)調適為受益於本揭示內容。
系統200包括真空氣密處理平台204、工廠介面202、及系統控制器244。平台204包括複數個處理腔室100、212、232、228、220(例如圖1中所描繪的處理腔室100中的該處理腔室)、及耦接到真空基板傳輸腔室236的至少一個裝載閘腔室222。圖2中示出了兩個裝載閘腔室222。工廠介面202被裝載閘腔室222耦接到傳輸腔室236。
在一個實施例中,工廠介面202包括至少一個對接站208及至少一個工廠介面機器人214以促進基板的傳輸。對接站208被配置為接受一或更多個前開式晶圓傳送盒(FOUP)。圖2的實施例中示出了兩個FOUP 206A-B。具有設置在機器人214的一端上的葉片216的工廠介面機器人214被配置為從工廠介面202向處理平台204傳輸基板以供通過裝載閘腔室222進行處理。可選地,可以將一或更多個度量站518連接到工廠介面202的終端226以促進測量來自FOUP 206A-B的基板。
裝載閘腔室222中的每一者具有耦接到工廠介面202的第一端口及耦接到傳輸腔室236的第二端口。裝載閘腔室222被耦接到壓力控制系統(未示出),該壓力控制系統將裝載閘腔室222抽空及通氣以促進在傳輸腔室236的真空環境與工廠介面202的實質周圍(例如大氣)環境之間傳遞基板。
傳輸腔室236具有設置在其中的真空機器人230。真空機器人230具有葉片234,該葉片能夠在裝載閘腔室222、度量系統210、及處理腔室212、232、228、220之中傳輸基板224。
在系統200的一個實施例中,系統200可以包括一或更多個處理腔室100、212、232、228、220,該一或更多個處理腔室可以是退火腔室(例如高壓退火腔室、RTP腔室、雷射退火腔室)、沉積腔室、蝕刻腔室、清潔腔室、固化腔室、或其他類似類型的半導體處理腔室。在系統200的一些實施例中,處理腔室100、212、232、228、220、傳輸腔室236、工廠介面202、及/或裝載閘腔室222中的至少一者中的一或更多者。
系統控制器244被耦接到處理系統200。系統控制器244(它可以包括計算設備201或被包括在計算設備201內)使用系統200的處理腔室100、212、232、228、220的直接控制來控制處理系統200的操作。或者,系統控制器244可以控制與處理腔室100、212、232、228、及系統200相關聯的電腦(或控制器)。操作時,系統控制器244也允許來自各別腔室的資料收集及反饋以最佳化系統200的效能。
與上述的計算設備201非常相似,系統控制器244一般包括中央處理單元(CPU)238、記憶體240、及支援電路242。CPU 238可以是可以用在工業環境中的任何形式的一般用途電腦處理器中的一者。支援電路242常規上被耦接到CPU 238,且可以包括快取記憶體、時脈電路、輸入/輸出子系統、電源等等。軟體常式將CPU 238轉換成特定用途電腦(控制器)244。也可以由定位在系統200遠端的第二控制器(未示出)儲存及/或執行軟體常式。
圖3描繪TFT設備350的實例,該TFT設備包括含金屬層,該含金屬層可以在高壓退火腔室中經歷熱退火過程,例如圖1中所描繪的高壓退火過程100,可以將該高壓退火腔室合併到圖2中所描繪的系統200中。薄膜電晶體設備結構350是設置在基板301上的底部閘極TFT結構。注意,基板301可以具有先前形成在該基板上的膜、結構、或層的不同組合以促進在基板301上形成不同的設備結構或不同的膜堆疊。在一個實例中,基板301可以具有形成於該基板上的設備結構350,如圖3中所示。或者,基板301可以具有設置於該基板上另一種設備結構450,如圖4中進一步示出,將在下文進一步描述該設備結構。基板301可以是玻璃基板、塑膠基板、聚合物基板、金屬基板、單個基板、卷對卷基板、或用於在其上形成薄膜電晶體的其他合適的透明基板中的任一者。
閘極電極層302被形成及圖案化在基板301上,之後是閘極絕緣層304。在一個實施例中,可以由任何合適的金屬材料製造閘極電極層302,例如鋁(Al)、鎢(W)、鉻(Cr)、鉭(Ta)、鉬(Mo)、銅(Cu)、或上述項目的組合。閘極絕緣體304的合適材料包括氧化矽(SiO2 )、氮氧化矽(SiON)、氮化矽(SiN)等等。注意,圖3中所描繪的薄膜電晶體設備結構350是底部閘極設備結構,其中閘極電極層302被形成於設備結構350的底部上。
有源層306被形成於閘極絕緣層304上。用於有源層306的材料可以選自具有高電子遷移率且適用於低溫製造的透明金屬氧化物材料,這允許在不損傷基板的情況下在低溫下處理柔性基板材料(例如塑膠材料)。可以用於有源層306的材料的合適實例包括a-IGZO(非晶銦鎵鋅氧化物)、InGaZnON、ZnO、ZnON、ZnSnO、CdSnO、GaSnO、TiSnO、CuBO2 、CuAlO2 、CuGaO2 、SrCuO、LaCuOS、GaN、InGaN、AlGaN、或InGaAlN等等。
在形成有源層306之後,可以將屏障層308形成於有源層306上。可以由含金屬材料形成屏障層308,以便向後續形成於該屏障層上的金屬電極層310(例如針對源極-汲極電極)提供良好的介面黏著以及良好的屏障性質(例如擴散屏障)。可以將屏障層308圖案化為在有源層306上形成所需的圖案以促進在後續的蝕刻過程中將特徵轉移在設置在基板301上的膜層上。儘管如圖3中所描繪的屏障層308被圖案化為所需的圖案,但注意,屏障層308可以呈現任何形式,依需要包括設備結構350中的整個連續空白膜或任何不同的特徵,只要屏障層308可以高效地提供阻擋/擴散屏障性質以防止來自有源層306的元素擴散到金屬電極層310中,反之亦然。在一個實施例中,屏障層308可以是由金屬介電層(例如依需要是Ta2 O5 或TiO2 或任何合適的金屬介電層)製造的單層的含金屬介電層,如圖3中所描繪。在另一個實施例中,屏障層308可以依需要呈現複合膜的形式。
在金屬電極層310(例如源極-汲極金屬電極層)被設置在屏障層308上方之後,隨後,執行蝕刻過程以在金屬電極層310中形成通道320。在蝕刻之後,絕緣材料層314(例如鈍化層)接著被形成在金屬電極層310上方以完成形成薄膜電晶體設備結構350的過程。
在一個實施例中,可以用作金屬電極層310的材料的實例包括銅(Cu)、金、銀(Ag)、鋁(Al)、鎢(W)、鉬(Mo)、鉻(Cr)、鉭(Ta)、上述項目的合金、及上述項目的組合。可以用作絕緣材料層314的合適材料包括氧化矽(SiO2 )、氮氧化矽(SiON)、或氮化矽(SiN)等等。
圖4描繪可以形成於基板301上的頂部閘極低溫多晶矽(LTPS)TFT設備結構450的實例,而不是圖3中所描繪的底部閘極設備結構350。LTPS TFT設備450是建造有有源層452的MOS設備,該等有源層包括形成於光學透明基板301上的源極區域409a、通道區域408、及汲極區域409b(例如,或稱為金屬接觸區域或源極-汲極金屬觸點),其中將或不將可選的絕緣層404設置在該光學透明基板上。在一個實例中,可以由透明的含金屬層(例如金屬氧化物材料)製造包括源極區域409a、通道區域408、及汲極區域409b的有源層,該透明的含金屬層具有高的電子遷移率及適於低溫製造,這允許在不損傷基板的情況下在低溫下處理柔性基板材料(例如塑膠材料)。可以用於源極區域409a、通道區域408、及汲極區域409b的此類材料的合適實例包括a-IGZO(非晶銦鎵鋅氧化物)、摻雜的IGZO、InGaZnON、ZnO、ZnON、ZnSnO、CdSnO、GaSnO、TiSnO、CuBO2 、CuAlO2 、CuGaO2 、SrCuO、LaCuOS、GaN、InGaN、AlGaN、或InGaAlN等等。
閘極絕緣層406接著被沉積於沉積的多晶矽層的頂部上,以將設置在該閘極絕緣層上的屏障層411及金屬電極層414(例如閘極電極)與通道區域408、源極區域409a、及汲極區域409b隔離。可以由含金屬材料形成屏障層411,以便向後續形成於該屏障層上的金屬電極層414(例如,閘極電極)提供良好的介面黏著以及良好的屏障性質(例如擴散屏障)。可以將屏障層411圖案化為在閘極絕緣層406上形成所需的圖案以促進在後續的蝕刻過程中將特徵轉移在設置在基板102上的膜層上。屏障層411可以高效地提供阻擋/擴散屏障性質,以防止來自閘極絕緣層406的元素擴散到金屬電極層414中,反之亦然。在一個實施例中,屏障層411可以是由金屬介電層(例如依需要是Ta2 O5 或TiO2 或任何合適的金屬介電層)製造的單層的含金屬介電層,如圖4中所描繪。在另一個實施例中,屏障層411可以依需要呈現複合膜的形式。
閘極電極層414被形成於閘極絕緣層406的頂部上,其中屏障層411介於其間。閘極絕緣層406通常也稱為閘極氧化物層,因為它通常是由二氧化矽(SiO2 )層製作的。絕緣材料層412(例如層間絕緣體)及設備連接件(未示出)接著被製作通過絕緣材料層412以允許控制TFT設備。
在絕緣材料層412形成之後,源極-汲極金屬電極層410a、410b接著被沉積、形成、及圖案化在絕緣材料層412中。在源極-汲極金屬電極層410a、410b被圖案化之後,鈍化層418接著被形成在源極-汲極金屬電極層410a、410b上方。
圖5描繪分別在含金屬層(例如分別在圖3-4中的有源層306、452、或分別在圖3-4中的金屬電極302、310、410a、410b、414)上執行的熱退火過程500的一個實例的流程圖。
方法500藉由提供基板(例如圖3及4中的基板301)開始於操作502處。基板301可以是光學透明基板。基板301可以包括設置在其上的材料層601,如圖6A中所示。材料層601可以是可以用來形成TFT設備結構的單個層或多個層。或者,材料層601可以是可以包括可以用來形成TFT設備結構的多種材料的結構。
基板301更包括形成於材料層601上的含金屬層602,如圖6B中所示。在不存在材料層601的實例中,可以將含金屬層602直接形成於基板301上。在一些實例中,可以將含金屬層602用作圖3或4中的有源層306、452、或圖3-4中的金屬電極302、310、410a、410b、414。在一個實例中,含金屬層602是選自由以下項目所組成的群組的金屬氧化物層:a-IGZO(非晶銦鎵鋅氧化物)、摻雜的IGZO、InGaZnON、ZnO、ZnON、ZnSnO、CdSnO、GaSnO、TiSnO、CuBO2 、CuAlO2 、CuGaO2 、SrCuO、LaCuOS、GaN、InGaN、AlGaN、或InGaAlN等等。在一個實例中,含金屬層602是IGZO或摻雜的IGZO層。或者,含金屬層602可以是金屬層,例如銅(Cu)、金、銀(Ag)、鋁(Al)、鎢(W)、鉬(Mo)、鉻(Cr)、鉭(Ta)、上述項目的合金等等。
在操作504處,執行可選的離子摻雜/植入過程以將離子植入到含金屬層602中,而形成摻雜的含金屬層610,如圖6C中所示。在離子植入過程被消除的實例中,可以直接在含金屬層602上執行操作506處的熱退火過程(下文將更詳細地描述)。離子摻雜/植入過程被執行為在含金屬層602的某些位置上進行摻雜、塗覆、處理、植入、安插、或更改某些膜/表面性質,其中摻雜物形成於該含金屬層中而形成摻雜的含金屬層610。離子摻雜/植入過程利用入射的離子來更改含金屬層602上的膜/表面性質,其中摻雜物被摻雜到該含金屬層以形成摻雜的含金屬層610。可以在任何合適的離子植入/摻雜處理工具中執行離子摻雜/植入過程。可以用所需的濃度將包括所需類型的原子的離子摻雜到含金屬層602中。摻雜到含金屬層602中的離子可以更改含金屬層602的膜/表面性質,這可以影響、改善、或變更含金屬層602的晶格結構、結晶度、鍵合結構、或膜密度,而形成摻雜的含金屬層610。
在含金屬層602包括InGaZnO的實施例中,摻雜到含金屬層602中的離子可以包括銦(In)或鉬(Mo)、鎵(Ga)、鋅(Zn)等等。據信,摻雜到含金屬層602(例如InGaZnO)中的In或Mo摻雜物可以變更InGaZnO材料的電氣性質,例如高遷移率、結晶度(例如來自非晶結構、C軸對準的晶體結構(CAAC)、多晶結構、或甚至單晶結構),因此提供了具有所需膜性質的摻雜的含金屬層610。例如,由InGaZnO材料中的In或Mo摻雜物所提供的較高程度的結晶度據信增加了膜性質的電子遷移率,因此在TFT設備結構或半導體設備中利用摻雜的含金屬層610時增強了TFT設備結構或半導體設備的電氣效能。
並且,也據信,包括在InGaZnO材料中的鎵(Ga)及氧化鋅(ZnO)比率也可以影響摻雜的含金屬層610的生成的晶格結構。據信,包括在InGaZnO材料中的Ga元素的比率可以增加膜透明度以及整體的膜帶隙。包括在InGaZnO材料中的Zn或ZnO元素的比率可以增加遷移率以及減小增強結晶度的熱退火溫度需求。因此,藉由選定摻雜到InGaZnO材料中的適當劑量的In摻雜物,可以獲得所需的InGaZnO材料晶體。並且,所需的InGaZnO材料晶體也可以幫助減小之後的操作506處的熱退火過程中的溫度需求,而在TFT設備應用中提供了過程優勢,因為基板301通常是具有相對低的熱循環預算的光學透明材料。
在一個實施例中,InGaZnO材料中的生成的In摻雜物可以具有形成於摻雜的含金屬層610中的在約5E15離子數/cm2 到約9E15離子數/cm2 之間(例如約8.5E15離子數/cm2 )的摻雜濃度。並且,可以將InGaZnO材料中的In或Mo元素的用原子量計的比率從約10%-13%增加到約14%-16%(在約15%到約30%之間的增加)。
可以在離子摻雜/植入過程期間控制幾個過程參數。可以藉由以下步驟來執行離子摻雜/植入過程:將離子摻雜氣體混合物以及所需的功率能量的量供應到離子摻雜/植入工具中以將來自離子摻雜氣體混合物的離子摻雜到基板301中。可以用在約10 sccm到約1000 sccm之間的流速將離子摻雜氣體混合物供應到離子摻雜/植入工具中。用於在植入期間在所使用的離子摻雜操作中用氣態供應的合適元素包括銦蒸氣及鉬蒸氣。可以將RF電力(例如電容式或感應式RF電力)、DC電力、電磁能、離子束、或磁控濺射供應到離子摻雜/植入過程中以協助在處理期間解離離子摻雜氣體混合物。可以使用藉由向基板支撐物或向基板支撐物上方的氣體入口或向該基板支撐物及該氣體入口施加DC或RF電偏壓產生的電場將由解離能所產生的離子朝向基板加速。在一些實施例中,含氣體的高能離子可以是電漿。可以使用在約20 keV到約80 keV之間(例如在約35 keV到約55 keV之間,例如約45 keV)的能量來將離子植入到含金屬層602中。可以將基板溫度控制在約攝氏5度到約攝氏50度之間,例如約攝氏15度。
在操作506處,執行高壓退火過程。在高過程壓力(例如大於2巴但小於)下執行的退火過程可以協助緻密化及修復摻雜的含金屬層610中的空位,而形成具有所需的膜性質的退火的含金屬層603,如圖6D中所示。在一些實例中,高的過程壓力可以高達100巴。在不執行操作504處的離子摻雜/植入過程的實施例中,可以直接在來自圖6B的含金屬層602上執行高壓退火過程以形成退火的含金屬層603,如圖6D中所示。可以在處理腔室(例如圖1中所描繪的處理腔室100)或其他合適的處理腔室(包括一次處理一個基板的彼等處理腔室)處執行退火過程。
在操作506處執行的高壓退火過程將高壓區域處的處理壓力維持在氣相(例如實質上不存在液滴的乾氣相)下。處理壓力及溫度被控制為緻密化膜結構,以便修復膜缺陷,而驅除雜質及增加膜密度。在一個實例中,高壓區域115被加壓到大於大氣的壓力,例如大於約2巴。在另一個實例中,高壓區域115被加壓到從約5到約100巴的壓力,例如從約5到約50巴,例如約35巴。因為高壓可以高效地協助緻密化膜結構,相對低的處理溫度(例如小於攝氏500度)減小了熱循環損傷基板301的可能性。
在處理期間,高壓區域115被設置在外腔室110內的加熱器122維持在相對低的溫度下,例如小於攝氏500度的溫度,例如在約攝氏150度到約攝氏350度之間。因此,可以藉由利用高壓退火過程以及低溫方案來獲得低的基板熱預算。
據信,高壓過程可以提供驅動力以驅除含金屬層602或摻雜的含金屬層610中的懸鍵,因此在退火過程期間使含金屬層602中的懸鍵修復、反應、及飽和。在一個實例中,可以在退火過程期間供應含氧氣體(例如O3 氣體、O2 氣體、空氣、H2 O、H2 O2 、N2 O、NO2 、CO2 、CO、及乾蒸氣)、或硫族蒸氣(包括硫(S)蒸氣及硒(Se)蒸氣)、或碲蒸氣、或其他合適的氣體。在一個具體實例中,含氧氣體包括蒸氣,例如乾蒸氣及/或空氣。可以將在退火過程期間來自含氧氣體的氧元素驅動到含金屬層602中,而變更其中的鍵合結構及移除原子空位,因此緻密化及增強了含金屬層602的晶格結構及增加了該含金屬層的結晶度。在一些實例中,可以與含氧氣體一起供應惰性氣體或載體氣體(例如Ar、N2 、He、Kr等等)。在一個實施例中,在含氧氣體混合物中供應的含氧氣體是在大於2巴的壓力下供應的乾蒸氣。
在一個示例性的實施方式中,過程壓力被調節在大於2巴的壓力下,例如在5巴到100巴之間,例如在20巴到約80巴之間,例如在約25巴到75巴之間,例如約35巴。可以將過程溫度控制在大於攝氏150度但小於攝氏500度,例如在約攝氏150度到約攝氏380度之間,例如在約攝氏180度到約攝氏400度之間。在一個實例中,可以在用於金屬氧硫族元素(例如包括S或Se的InGaZnO)的退火過程期間供應硫族蒸氣(例如硫(S)蒸氣、硒(Se)蒸氣)。
在高壓下的退火過程之後,與藉由一個大氣壓力左右的壓力下的常規退火過程來退火的含金屬層602或摻雜的含金屬層610相比,含金屬層602或摻雜的含金屬層610具有緻密化的膜結構,這提供了具有非晶形態的相對強健的膜結構,該膜結構提供了更高的膜密度、高的膜遷移率、低的載體濃度、及低的膜電阻率,其中兩種退火過程都處於相同的退火溫度。在一個實例中,與1大氣壓力下且相同退火溫度下的常規退火過程相比,具有銦摻雜物的高壓退火的含金屬層603(由摻雜的含金屬層610所形成)的遷移率增加了約5倍到約20倍之間,電阻率增加了約10倍,且載體濃度減小了約100倍。
在一個實例中,與1大氣壓力下且相同退火溫度下的常規退火過程相比,不具有銦摻雜物的高壓退火的含金屬層603(由含金屬層602所形成)的遷移率增加了約1.5倍到約5倍之間,電阻率增加了約20百分比到約99百分比,且載體濃度減小了約100倍。
因此,提供了用於熱退火含金屬層的方法。可以藉由具有高過程壓力(例如大於2巴但小於50巴)的高壓退火過程來熱處理/退火含金屬層。藉由利用此類高壓退火過程,可以將過程溫度維持小於攝氏500度,因此減小了貢獻給其上形成有含金屬層的基板的熱預算,而提供了具有所需的結晶度及結構整合管理的良好膜品質。
儘管上文是針對本發明的實施例,但可以設計本發明的其他的及另外的實施例而不脫離本發明的基本範圍,且本發明的範圍是由隨後的申請專利範圍所決定的。
100‧‧‧單基板處理腔室 110‧‧‧主體 111‧‧‧開口 112‧‧‧外表面 113‧‧‧內表面 114‧‧‧壓力感測器 115‧‧‧內部容積 116‧‧‧溫度感測器 117‧‧‧端口 119‧‧‧溫度感測器 122‧‧‧加熱器 130‧‧‧基板支撐物 131‧‧‧電阻式加熱元件 132‧‧‧基板支撐構件 133‧‧‧電源 134‧‧‧桿 135‧‧‧板 136‧‧‧孔 137‧‧‧升降銷 138‧‧‧致動器 139‧‧‧桿 140‧‧‧加熱器 145‧‧‧電源 150‧‧‧氣體面板 151‧‧‧溫度感測器 152‧‧‧加熱器 153‧‧‧溫度感測器 154‧‧‧加熱器 155‧‧‧入口隔離閥 156‧‧‧溫度讀數設備 157‧‧‧來源導管 158‧‧‧加熱器 160‧‧‧冷凝器 162‧‧‧溫度讀數設備 163‧‧‧排氣導管 164‧‧‧加熱器 165‧‧‧出口隔離閥 166‧‧‧加熱器 167‧‧‧溫度感測器 169‧‧‧溫度感測器 170‧‧‧泵 176‧‧‧泵 180‧‧‧控制器 190‧‧‧流體迴路 192‧‧‧導氣管 196‧‧‧加熱器 200‧‧‧處理系統 201‧‧‧計算設備 202‧‧‧工廠介面 204‧‧‧真空氣密處理平台 206A‧‧‧FOUP 206B‧‧‧FOUP 208‧‧‧對接站 212‧‧‧處理腔室 214‧‧‧工廠介面機器人 216‧‧‧葉片 220‧‧‧處理腔室 222‧‧‧裝載閘腔室 224‧‧‧基板 226‧‧‧終端 228‧‧‧處理腔室 230‧‧‧真空機器人 232‧‧‧處理腔室 234‧‧‧葉片 236‧‧‧真空基板傳輸腔室 238‧‧‧CPU 240‧‧‧記憶體 242‧‧‧支援電路 244‧‧‧系統控制器 301‧‧‧基板 302‧‧‧金屬電極 304‧‧‧閘極絕緣體 306‧‧‧有源層 308‧‧‧屏障層 310‧‧‧金屬電極 314‧‧‧絕緣材料層 320‧‧‧通道 350‧‧‧設備結構 404‧‧‧絕緣層 406‧‧‧閘極絕緣層 408‧‧‧通道區域 409a‧‧‧源極區域 409b‧‧‧汲極區域 410a‧‧‧金屬電極 410b‧‧‧金屬電極 411‧‧‧屏障層 412‧‧‧絕緣材料層 414‧‧‧金屬電極 418‧‧‧鈍化層 450‧‧‧設備結構 500‧‧‧熱退火過程 502‧‧‧操作 504‧‧‧操作 506‧‧‧操作 508‧‧‧操作 601‧‧‧材料層 602‧‧‧含金屬層 603‧‧‧退火的含金屬層 610‧‧‧摻雜的含金屬層
可以藉由參照實施例來獲得可以用來詳細瞭解上文所載的本發明特徵的方式及上文簡要概述的本發明的更特定描述,該等實施例中的一些被繪示在附圖中。然而,應注意,附圖僅繪示此發明的典型實施例且因此不要將其視為此發明的範圍限制,因為本發明可以容許其他同等有效的實施例。
圖1是依據一些實施例的處理腔室的簡化正橫截面圖,該處理腔室具有設置在其中的輸送盒;
圖2是群集系統,可以將圖1的處理腔室合併到該群集系統;
圖3是薄膜電晶體設備結構的一個實例的截面圖;及
圖4是薄膜電晶體設備結構的另一個實例的截面圖。
圖5描繪依據一些實施例的在含金屬材料中執行的退火過程的流程圖;
圖6A-6D描繪依據一些實施例的圖5的用於將含金屬材料熱退火的序列的一個實施例。
為了促進了解,已經儘可能使用相同的參考標號(例如類似退火條件下的大氣壓力下的退火)來標定圖式共有的相同元件。所預期的是,可以在不另外重述的情況下有益地將一個實施例的元件及特徵併入其他實施例。
然而,要注意,附圖僅繪示此發明的示例性實施例,且因此不要將該等附圖視為此發明的範圍的限制,因為本發明可以容許其他同等有效的實施例。
國內寄存資訊 (請依寄存機構、日期、號碼順序註記) 無
國外寄存資訊 (請依寄存國家、機構、日期、號碼順序註記) 無
100‧‧‧單基板處理腔室
110‧‧‧主體
111‧‧‧開口
112‧‧‧外表面
113‧‧‧內表面
114‧‧‧壓力感測器
115‧‧‧內部容積
116‧‧‧溫度感測器
117‧‧‧端口
119‧‧‧溫度感測器
122‧‧‧加熱器
130‧‧‧基板支撐物
131‧‧‧電阻式加熱元件
132‧‧‧基板支撐構件
133‧‧‧電源
134‧‧‧桿
135‧‧‧板
136‧‧‧孔
137‧‧‧升降銷
138‧‧‧致動器
139‧‧‧桿
140‧‧‧加熱器
145‧‧‧電源
150‧‧‧氣體面板
151‧‧‧溫度感測器
152‧‧‧加熱器
153‧‧‧溫度感測器
154‧‧‧加熱器
155‧‧‧入口隔離閥
156‧‧‧溫度讀數設備
157‧‧‧來源導管
158‧‧‧加熱器
160‧‧‧冷凝器
162‧‧‧溫度讀數設備
163‧‧‧排氣導管
164‧‧‧加熱器
165‧‧‧出口隔離閥
166‧‧‧加熱器
167‧‧‧溫度感測器
169‧‧‧溫度感測器
170‧‧‧泵
176‧‧‧泵
180‧‧‧控制器
190‧‧‧流體迴路
192‧‧‧導氣管
196‧‧‧加熱器

Claims (15)

  1. 一種在一基板上形成一含金屬層的方法,該方法包括以下步驟:在一處理腔室中的一基板上供應一含氧氣體混合物,該基板包括設置在一光學透明基板上的一含金屬層;將該處理腔室中的該含氧氣體混合物維持在2巴到50巴之間的一過程壓力下;及在一基板溫度下在該含氧氣體混合物存在的情況下熱退火該含金屬層,其中:該含氧氣體混合物包括一含氧氣體、及一惰性氣體或一載體氣體,該含金屬層是一金屬氧化物層或一金屬層,該金屬氧化物層選自由以下項目所組成的一群組:a-IGZO(非晶銦鎵鋅氧化物)、摻雜的IGZO、InGaZnON、ZnO、ZnON、ZnSnO、CdSnO、GaSnO、TiSnO、CuBO2、CuAlO2、CuGaO2、SrCuO、LaCuOS、GaN、InGaN、AlGaN、及InGaAlN,該金屬層選自由以下項目所組成的一群組:鋁(Al)、鎢(W)、鉻(Cr)、鉭(Ta)、鉬(Mo)、銅(Cu)、上述項目的合金、及上述項目的組合,及 在該熱退火步驟之後,與藉由在1大氣壓力下且在與該基板溫度相同的溫度下進行的一退火過程來退火的該含金屬層的遷移率相比,該含金屬層的遷移率增加了約1.5倍到20倍之間。
  2. 如請求項1所述的方法,其中供應該含氧氣體混合物的步驟更包括以下步驟:將該基板溫度維持小於攝氏400度。
  3. 如請求項1所述的方法,其中該含氧氣體選自由以下項目所組成的一群組:O3氣體、O2氣體、H2O、H2O2、N2O、NO2、CO2、CO、空氣、乾蒸氣。
  4. 如請求項1所述的方法,其中含氧氣體混合物包括乾蒸氣或空氣。
  5. 如請求項1所述的方法,其中該過程壓力是在約5巴到100巴之間。
  6. 如請求項1所述的方法,更包括以下步驟:在供應該含氧氣體混合物之前將摻雜物植入到該含金屬層中。
  7. 如請求項6所述的方法,其中植入到該含金屬層中的該等摻雜物包括銦或鉬。
  8. 如請求項7所述的方法,其中植入到該含金屬層中的該等摻雜物增加了該含金屬層的結晶度。
  9. 如請求項1所述的方法,其中該含金屬層是一TFT設備結構中的一有源層。
  10. 如請求項1所述的方法,其中該金屬氧化物層是InGaZnON。
  11. 如請求項1所述的方法,其中該含金屬層是一TFT設備結構中的一電極。
  12. 如請求項1所述的方法,其中該含金屬層在該熱退火步驟之後具有較高的一膜密度。
  13. 一種用於緻密化設置在一基板上的一含金屬層的方法,該方法包括以下步驟:在2巴到50巴之間的一壓力下熱處理設置在一光學透明基板上的一含金屬層;及在熱處理該含金屬層的期間將一基板溫度維持小於攝氏500度,其中:該含金屬層是一金屬氧化物層或一金屬層,該金屬氧化物層選自由以下項目所組成的一群組:a-IGZO(非晶銦鎵鋅氧化物)、摻雜的IGZO、InGaZnON、ZnO、ZnON、ZnSnO、CdSnO、GaSnO、TiSnO、CuBO2、CuAlO2、CuGaO2、SrCuO、LaCuOS、GaN、InGaN、AlGaN、及InGaAlN, 該金屬層選自由以下項目所組成的一群組:鋁(Al)、鎢(W)、鉻(Cr)、鉭(Ta)、鉬(Mo)、銅(Cu)、上述項目的合金、及上述項目的組合,及在該熱處理步驟之後,與藉由在1大氣壓力下且在與該基板溫度相同的溫度下進行的一熱處理過程來退火的該含金屬層的遷移率相比,該含金屬層的遷移率增加了約1.5倍到20倍之間。
  14. 如請求項13所述的方法,更包括以下步驟:在熱處理該含金屬層的同時向該含金屬層供應乾蒸氣、空氣、硫族蒸氣、或碲蒸氣。
  15. 一種用於緻密化設置在一基板上的一含金屬層的方法,該方法包括以下步驟:在一基板上形成一含金屬層;將摻雜物植入到該含金屬層中;及在2巴到50巴之間的一壓力下熱處理該基板上的該含金屬層,同時將一基板溫度維持小於攝氏500度,其中:該含金屬層是一金屬氧化物層或一金屬層,該金屬氧化物層選自由以下項目所組成的一群組:a-IGZO(非晶銦鎵鋅氧化物)、摻雜的IGZO、InGaZnON、ZnO、ZnON、ZnSnO、CdSnO、GaSnO、TiSnO、CuBO2、CuAlO2、CuGaO2、 SrCuO、LaCuOS、GaN、InGaN、AlGaN、及InGaAlN,該金屬層選自由以下項目所組成的一群組:鋁(Al)、鎢(W)、鉻(Cr)、鉭(Ta)、鉬(Mo)、銅(Cu)、上述項目的合金、及上述項目的組合,及在該熱處理步驟之後,與藉由在1大氣壓力下且在與該基板溫度相同的溫度下進行的一熱處理過程來退火的該含金屬層的遷移率相比,該含金屬層的遷移率增加了約1.5倍到20倍之間。
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