WO2006045885A1 - Method of depositing lead containing oxides films - Google Patents

Method of depositing lead containing oxides films Download PDF

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Publication number
WO2006045885A1
WO2006045885A1 PCT/FI2005/000461 FI2005000461W WO2006045885A1 WO 2006045885 A1 WO2006045885 A1 WO 2006045885A1 FI 2005000461 W FI2005000461 W FI 2005000461W WO 2006045885 A1 WO2006045885 A1 WO 2006045885A1
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Prior art keywords
lead
metal
process according
source material
oxygen
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PCT/FI2005/000461
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French (fr)
Inventor
Matti I. Putkonen
Jenni E. Harjuoja
Hannu Huotari
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Asm International N.V.
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Priority claimed from US10/974,487 external-priority patent/US20060088660A1/en
Application filed by Asm International N.V. filed Critical Asm International N.V.
Priority to JP2007538452A priority Critical patent/JP5025484B2/en
Publication of WO2006045885A1 publication Critical patent/WO2006045885A1/en

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    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22Chemical 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 deposition of inorganic material, other than metallic material
    • C23C16/30Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40Oxides
    • C23C16/409Oxides of the type ABO3 with A representing alkali, alkaline earth metal or lead and B representing a refractory metal, nickel, scandium or a lanthanide
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44Chemical 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
    • C23C16/455Chemical 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
    • C23C16/45523Pulsed gas flow or change of composition over time
    • C23C16/45525Atomic layer deposition [ALD]
    • C23C16/45527Atomic layer deposition [ALD] characterized by the ALD cycle, e.g. different flows or temperatures during half-reactions, unusual pulsing sequence, use of precursor mixtures or auxiliary reactants or activations
    • C23C16/45531Atomic layer deposition [ALD] characterized by the ALD cycle, e.g. different flows or temperatures during half-reactions, unusual pulsing sequence, use of precursor mixtures or auxiliary reactants or activations specially adapted for making ternary or higher compositions
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44Chemical 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
    • C23C16/455Chemical 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
    • C23C16/45523Pulsed gas flow or change of composition over time
    • C23C16/45525Atomic layer deposition [ALD]
    • C23C16/45553Atomic layer deposition [ALD] characterized by the use of precursors specially adapted for ALD
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B25/00Single-crystal growth by chemical reaction of reactive gases, e.g. chemical vapour-deposition growth
    • C30B25/02Epitaxial-layer growth
    • C30B25/14Feed and outlet means for the gases; Modifying the flow of the reactive gases
    • CCHEMISTRY; METALLURGY
    • C30CRYSTAL GROWTH
    • C30BSINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
    • C30B29/00Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
    • C30B29/10Inorganic compounds or compositions
    • C30B29/16Oxides
    • C30B29/22Complex oxides
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/02104Forming layers
    • H01L21/02107Forming insulating materials on a substrate
    • H01L21/02109Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates
    • H01L21/02112Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer
    • H01L21/02172Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing at least one metal element, e.g. metal oxides, metal nitrides, metal oxynitrides or metal carbides
    • H01L21/02197Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing at least one metal element, e.g. metal oxides, metal nitrides, metal oxynitrides or metal carbides the material having a perovskite structure, e.g. BaTiO3
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/02104Forming layers
    • H01L21/02107Forming insulating materials on a substrate
    • H01L21/02225Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer
    • H01L21/0226Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process
    • H01L21/02263Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase
    • H01L21/02271Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase deposition by decomposition or reaction of gaseous or vapour phase compounds, i.e. chemical vapour deposition
    • H01L21/0228Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase deposition by decomposition or reaction of gaseous or vapour phase compounds, i.e. chemical vapour deposition deposition by cyclic CVD, e.g. ALD, ALE, pulsed CVD
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
    • H01L21/18Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic System or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H01L21/31Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to form insulating layers thereon, e.g. for masking or by using photolithographic techniques; After treatment of these layers; Selection of materials for these layers

Definitions

  • the presents invention relates generally to the field of microelectronics and in particular to methods of producing lead containing oxide thin films by gas phase deposition methods and, more particular, by atomic layer deposition (ALD), and to lead containing oxide thin films.
  • ALD atomic layer deposition
  • the lead titanate (PT) family consists of a large range of solid compounds, such as PZT (lead zirconate titanate), PLT (lead lanthanum titanate) and PLZT (lead lanthanum zirconate titanate).
  • PZT lead zirconate titanate
  • PLT lead lanthanum titanate
  • PLZT lead lanthanum zirconate titanate
  • dopants e.g. lanthanum and zirconium
  • MIS metal-insulator- semiconductor
  • MIM metal-insulator- metal
  • Lead niobates such as lead magnesium niobate (PMN) and lead zinc niobate (PZN), have also similar properties and possibilities to similar applications than lead titanates. Properties, such as dielectric constant, can be increased by mixing, for example, lead magnesium niobate (PbMgNbO 3 ) with lead titanates to form PMN-PT material. Further to this, PMN-PT material can be mixed with barium titanate (BT) to form PMN-PT-BT material.
  • PbMgNbO 3 lead magnesium niobate
  • BT barium titanate
  • the perovskite-type PbTiO 3 has a high Curie temperature of 490 0 C, a relatively low permittivity (compared to other lead titanate family compounds) and a large pyroelectric coefficient.
  • Lead titanate thin films have basically the same physical properties as the bulk material but in memory applications they have low operating voltage and high switching speed.
  • the material PbMgNbO 3 + PbTiO 3 (PMN-PT) has a very high k-value of about 22600.
  • the material PbMgNbO3 itself has also a high k-value of about 7000.
  • Thin films of above mentioned materials, such as PT, PZT, PMN, PMN-PT, have been prepared by different chemical and physical methods.
  • Metal-organic chemical vapor deposition (MOCVD), with all its different variations, such as laser induced-MOCVD, plasma induced-MOCVD and ion beam induced-MOCVD, is the most used deposition method. Ih addition to conventional CVD methods, the so-called “improved MOCVD” method has been used to deposit a- and c-axis-oriented thin films. In such a method, the metal precursor vapors have been alternately introduced into the reactor together with the oxygen source.
  • Other chemical and physical deposition methods used for preparing thin films of PbTiO 3 include rf magnetron sputtering, pulsed laser ablation, the sol-gel method, spin-coating, chemical solution deposition and hybrid chemical methods.
  • the lead containing oxide thin films have to meet stringent quality demands.
  • the films have to be defect-free and they must have low surface roughness.
  • the interface between the ferroelectric and the substrate is important. To avoid undesirable interfacial reactions during the semiconductor process, a low deposition temperature is preferred.
  • Atomic Layer Deposition (ALD - or, as it was earlier called, "Atomic Layer Epitaxy”, abbreviated ALE) is a well-known method for growing high-quality thin films on substrates.
  • ALD method is based on sequential self- saturating surface reactions resulting in thin films that have low impurity content and uniform physical properties including film thickness.
  • a reference is made to the following two publications.
  • lead oxide exists in many different forms because lead can adopt a valence state of either +2 or +4. Lead oxides have also many different crystal forms. Consequently, it is difficult to deposit lead oxide thin films containing only one oxide form with a certain crystal form. Earlier studies have shown that lead oxide thin films deposited by metal organic chemical vapor deposition (MOCVD) contain both lead oxide and oxygen rich form of lead dioxide.
  • MOCVD metal organic chemical vapor deposition
  • lead oxide containing thin films such as high performance lead titanate (PbTiO 3 ) or lead magnesium niobate (PbMgNbO 3 ) for thin film applications.
  • binary lead oxides and ternary, quaternary and more complicated metal oxides containing lead oxide can be grown by the ALD process from metal-organic lead precursors that contain organic ligands bonded to the lead atom of the compound by carbon-metal bonds.
  • metal-organic lead precursors that contain organic ligands bonded to the lead atom of the compound by carbon-metal bonds.
  • traditional organo metallic precursors in which the metal is bonded to the organic residues via oxygen atoms do not give rise to genuine ALD growth, or ALD growth is achieved only within narrow temperature ranges, and films produced exhibit high levels of impurities.
  • the present lead precursors result in ALD growth within various (broad) temperature ranges and the thin films have very low concentrations of residues from the ligands.
  • the present invention also provides a process for forming lead containing multicomponent oxide thin films by Atomic Layer Deposition on a substrate in a reaction space.
  • the method of producing thin firms according to the present invention is mainly characterized by what is stated in the characterizing part of claim 1.
  • the method for producing multicomponent lead oxide firms is mainly characterized by what is stated in the characterizing part of claim 23.
  • stoichiometric PbTiO 3 thin films with excellent uniformity can be deposited on substrates by ALD growth using, for example, Ph 4 Pb, O 3 , Ti(O 1 Pr) 4 and H 2 O as precursors at substrate temperatures of 250 and 300 °C.
  • a stoichiometric PbMgNbO 3 thin films with excellent uniformity can be deposited on substrates by ALD growth using, for example, Ph 4 Pb, Mg(Cp) 2 , Nb(OEt) 5 and O 3 and/or H 2 O as precursors at substrate temperatures of 250 and 300 0 C.
  • the film thickness of PbTiO 3 films has been found to be linearly dependent on the number of deposition cycles, indicating genuine ALD growth.
  • thin films produced by the present invention typically contain only small amounts of hydrogen and carbon impurities according to Time-of-Flight Elastic Recoil Detection Analysis (TOF-ERDA).
  • TOF-ERDA Time-of-Flight Elastic Recoil Detection Analysis
  • Lead titanate films are amorphous after deposition, but crystalline PbTiO 3 thin films can be obtained according to the process of the invention by annealing the amorphous films at temperatures above 500 0 C, e.g. 600 0 C, or more. By converting the amorphous films into crystalline firms, higher dielectric constants are obtained. Next the invention will be discussed more closely with the aid of a detailed description and a working example.
  • FIG. 1 shows a structural and a shaded ball drawing of a tetraphenyllead Ph 4 Pb molecule.
  • FIG. 2 shows an example of a process sequence used for depositing a multimetal oxide thin film.
  • FIG. 3 shows the growth rate Of PbO 2 thin films as a function of deposition temperature.
  • FIG. 4 shows x-ray diffraction diagrams of PbO 2 films deposited from selected Pb precursors.
  • FIG. 5 shows the deposition rate of lead oxide thin films at selected temperatures deposited from Ph 4 Pb with different material pulse lengths.
  • FIG. 6 shows the effect of Ti / Pb precursor pulsing ratio on the titanium and lead content in Pb-Ti-O films deposited at selected temperatures.
  • FIG. 7 shows the effect of annealing on PbTiO 3 firms revealed by x-ray diffraction diagrams.
  • PEALD plasma enhanced ALD
  • thermal ALD refers to an ALD method where plasma is not used but where the substrate temperature is high enough for overcoming the energy barrier (activation energy) during collisions between the chemisorbed species on the surface and reactant molecules in the gas phase so that up to an atomic (elemental) or a molecular (compound) layer of thin film grows on the substrate surface during each ALD pulsing sequence.
  • ALD covers both PEALD and thermal ALD.
  • an ALD type process generally refers to a process for producing thin films over a substrate, in which process a solid thin film is formed molecular layer by molecular layer due to self- saturating chemical reactions on heated surfaces.
  • gaseous reactants i.e. precursors
  • a reaction space of an ALD type of a reactor and contacted with a substrate located in the chamber to provide a surface reaction.
  • the pressure and the temperature of the reaction space are adjusted to a range where physisorption (i.e. condensation of gases) and thermal decomposition of the precursors are avoided. Consequently, only up to one monolayer (i.e.
  • an atomic layer or a molecular layer) of material is deposited at a time during each pulsing cycle.
  • the actual growth rate of the thin film which is typically presented as A/pulsing cycle, depends, for example, on the number of available reactive surface sites on the heated surface and bulkiness of the chemisorbing molecules. Gas phase reactions between precursors and any undesired reactions of by-products are inhibited because material pulses are separated from each other by time and the reaction space is purged with an inactive gas (e.g. nitrogen or argon) or evacuated between material pulses to remove surplus gaseous reactants and reaction by-products from the chamber.
  • an inactive gas e.g. nitrogen or argon
  • a reaction space designates generally a reactor or a reaction chamber in which the conditions can be adjusted so that deposition of a thin film is possible.
  • an ALD type reactor means a reactor where the reaction space is in fluid communication with an inactive gas source and at least one, preferably at least two precursor sources that can be pulsed, i.e. the precursor vapour pushed from the precursor source can be introduced as a gas pulse into the reaction space, the reaction space is in fluid communication with a vacuum generator (e.g. a vacuum pump), and the temperature and pressure of the reaction space and the flow rates of gases can be adjusted to a range that makes it possible to grow thin films by ALD type processes.
  • a vacuum generator e.g. a vacuum pump
  • rare earths means elements of the group 3 (scandium Sc, yttrium Y, lanthanum La) and lanthanide series (cerium Ce, praseodymium Pr, neodymium Nd, samarium Sm, europium Eu, gadolinium Gd, terbium Tb, dysprosium Dy, holmium Ho, erbium Er, thulium Tm, ytterbium Yb and lutetium Lu) of the periodic table of elements.
  • Source material and “precursor” are used interchangeably in the present application to designate a volatile or gaseous compound, which can be used as a starting compound for the corresponding metal oxide of the thin film.
  • Multicomponent oxide films stands for films comprising oxides of at least 2 metal species, typically 2 to 4 metal species. Such films may comprise oxides such as Pb(Zr, Ti)O 3 or Pb(Mg, Nb)O 3 , but they may also be formed by two or more different oxides, such as multicomponent oxide thin film comprising both Pb(Mg, Nb)O 3 and PbTiO 3 . There may even be three oxide components in the multicomponent oxide thin film, such as Pb(Mg, Nb)O 3 , PbTiO 3 and BaTiO 3 .
  • metal-organic lead precursors containing organic ligands which are bonded to the lead atom via carbon-lead bonds are used as source materials in the production of thin films in ALD reactors.
  • the metal-organic lead compound has 2 or 4 alkyl ligands or ligands comprising aromatic groups.
  • the metal-organic lead compound has the formula
  • each L 1 , L 2 , L 3 and L 4 is independently selected from
  • carbocyclic groups such as aryl, preferably phenyl, tolyl and xylyl, alkylaryl groups including benzyl, cyclic dienes, halogenated carbocyclic groups, and
  • the precursors contain four organic ligands selected from the group of optionally substituted, linear, branched or cyclic alkyl groups or aryl groups.
  • Alkyl stands, for example, for an alkyl group, selected from methyl, ethyl, n- and i-propyl, and n-, sec- and t-butyl.
  • the alkyl groups may be the same or different.
  • the chlorinated alkyl and alkenyl groups are mentioned.
  • Other substituents are also possible, such as hydroxyl, carboxy, thio, silyl and amino groups.
  • FIG. 1 depicts a structural 100 and a shaded ball drawing 110 of a tetraphenyllead Ph 4 Pb molecule.
  • the molecules consists of lead 102, carbon 104 and hydrogen 106 atoms. It can be seen that the Pb atom 102 in the center of the Ph 4 Pb molecule is shielded with phenyl C 6 Hs ligands resulting in good thermal stability of the precursor.
  • Second metal source material needed for ternary or higher metal oxides can be a metal compound or a complex metal compound comprising two or several metals.
  • the metals are typically selected from the group of volatile or gaseous compounds of transition metals and main group metals according to the system recommended by IUPAC in the periodic table of elements, i.e., elements of groups comprising
  • - 2 Mg, Ca, Sr, Ba
  • - 3 Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu
  • - 12 Zn, Cd, Hg
  • - 13 Al, Ga, In, Tl
  • each metal compound varys, the suitability of each metal compound for the use in the process of the present invention has to be considered.
  • the properties of the compounds are found, e.g., in N. N. Greenwood and A. Earnshaw, Chemistry of the Elements, 1 st edition, Pergamon Press, 1986.
  • suitable second metal source materials are preferably selected from the group comprising
  • halides preferably fluorides, chlorides, bromides or iodides
  • alkoxides cf. the titanium isopropoxide of the Example 1 and niobium ethoxide
  • alkylamino cf. the titanium isopropoxide of the Example 1 and niobium ethoxide
  • Double metal precursors i.e. molecules containing two metals in a discrete stoichiometric ratio
  • Examples of double metal precursors include double metal alkoxides that have been presented, e.g., in a chemical catalogue from Gelest, Inc. (Edited by B. Arkles, Gelest, Inc. 1995, pp. 344-346).
  • the oxygen source material is preferably selected from the group comprising
  • alcohols such as methanol, ethanol, propanol and isopropanol
  • Ozone gas is often diluted with oxygen gas due to the ozone manufacturing methods.
  • the oxygen precursor vapor is optionally diluted with inactive gas.
  • the reaction temperature can vary depending on the evaporation temperature and the decomposition temperature of the precursor.
  • a typical range is represented by about 150 to 400 °C, in particular about 180 to 380 °C.
  • gas phase pulses of the evaporated metal-organic lead compound mixed with inactive carrier gas or without the inactive carrier gas are introduced into an ALD reactor, in which they are contacted with a suitable substrate.
  • the deposition can be carried out at normal pressure, but it is preferred to operate the method at reduced pressure.
  • the pressure in the reactor is typically 0.01 - 20 mbar, preferably 0.1 - 5 mbar.
  • the substrate temperature has to be low enough to keep the bonds between thin film atoms intact and to prevent thermal decomposition of the gaseous reactants.
  • the substrate temperature has to be high enough to keep the source materials in gaseous phase, i.e., condensation of the gaseous reactants must be avoided. Further, the temperature must be sufficiently high to provide the activation energy for the surface reaction.
  • the substrate can be of various types. Examples include silicon, silica, coated silicon, germanium, silicon-germanium alloys, copper metal, noble and platinum metals group including silver, gold, platinum, palladium, rhodium, iridium and ruthenium, various nitrides, such as transition metal nitrides, e.g. tantalum nitride TaN, various oxides, such as platinum group metal oxides, e.g. ruthenium dioxide RuO 2 , various carbides, such as transition metal carbides, e.g.
  • tungsten carbide WC transition metal nitride carbides, e.g. tungsten nitride carbide WN x Cy and dielectric surfaces, such as high-k oxides serving as interfacial layers, e.g. Al 2 O 3 or La 2 O 3 being an example of rare earth oxides.
  • transition metal nitride carbides e.g. tungsten nitride carbide WN x Cy
  • dielectric surfaces such as high-k oxides serving as interfacial layers, e.g. Al 2 O 3 or La 2 O 3 being an example of rare earth oxides.
  • MM metal-insulator-metal
  • the preceding thin film layer deposited will form the substrate surface for the next thin film.
  • the reactor In order to convert the adsorbed (chemisorbed) lead precursor into lead oxide, the reactor is evacuated and/or purged with a purge gas comprising an inactive gas, and then a next gas phase pulse of an oxygen source material, such as ozone O 3 , is introduced into the reactor.
  • the oxygen precursor vapor is optionally diluted with inactive gas.
  • a lead containing oxide thin film can be deposited.
  • a growth rate of about 0.10 to 0.20 A/cycle is achieved.
  • a second metal source material can be introduced at ALD conditions.
  • a multicomponent oxide film consists essentially of Pb oxide and of an oxide preferably selected from Bi, Ca, Ba, Sr, Cu, Ti, Ta, Zr, Hf, V, Nb, Zn, Cr, W, Mo, Al, rare earths (e.g. La) and/or Si oxides and, thus, the corresponding gaseous or volatile metal compounds are preferably used in the method of the present invention.
  • the second (third etc.) metal source material can be oxidized using the same or another oxygen source material as for the lead precursor.
  • Titanium, lanthanum and zirconium are particularly interesting as sources of a second and/or third and/or fourth metal in ternary and other multicomponent lead containing . oxides.
  • Niobium, magnesium and zinc are particularly interesting as sources of a second and/or third and/or fourth metal in ternary and other multicomponent lead containing oxides.
  • Multicomponent Pb/Ti and Pb/Ti and La and/or Zr or multicomponent Pb/Nb and Pb/Nb and Mg oxides are potentially valuable as high-k dielectric material.
  • multicomponent films are produced by feeding alternating pulses of the various metal precursors (followed by the above mentioned oxygen source pulses) into an ALD reactor.
  • This embodiment based on “mixing cycles” will give rise to a ferroelectric phase after deposition.
  • the ratio of cycles consisting of lead containing precursor followed by oxygen source pulses to cycles consisting of a second metal source followed by the corresponding oxygen source pulses is about 50:1...1:50, preferably about 40:1 to 1:40, in particular about 35:1...1:1 (metal to metal, based on moles).
  • a stoichiometric oxide ABO 3 wherein A and B denote two different metals, can be obtained simply by pulsing the two metal precursors and corresponding oxygen sources alternately and the growth rate of the ternary oxide can be predicted by summing the growth rates of the constituent oxides.
  • both assumptions often fail due to the different reactivities of the precursors.
  • the effect of surface chemistry usually causes changes in relative growth rate, which can be determined by comparing the observed firm thickness with the theoretical thickness calculated from the growth rates of binary oxides.
  • the relative growth rate of PbTiO 3 was found to be dependent on the pulsing ratio of precursors and also on the deposition temperature.
  • Another preferred embodiment comprises preparing multicomponent films by depositing laminar layers of each metal oxide and by annealing the laminar layers together at increased temperatures to provide a crystalline phase.
  • a high dielectric material is obtained by annealing in the presence of oxygen (such as in the presence of air) at temperatures in excess of 500 0 C, in particular in excess of 700 °C, in the presence of an oxygen-containing compound (e.g. N 2 O) or in the presence of an inert gas (e.g. N 2 or Ar).
  • the polycrystalline tetragonal perovskite PbTiO 3 phase (JCPDS Card No 6-452) can be observed by XRD when stoichiometric or lead-rich films deposited at 250 0 C are annealed either in nitrogen or oxygen atmosphere for at least 1 minute, preferably for 5 to 60 minutes, typically about 10 minutes, at a temperature in the range of 600 to 900 0 C.
  • Annealing in oxygen is a particularly preferred way of crystallizing PbTiO 3 for lead oxide films deposited at 250 °C. Films annealed in oxygen are smooth and shiny even after annealing at 900 °C.
  • annealing in nitrogen is a preferred embodiment for the films deposited at 300 °C.
  • a gas phase pulse of an oxygen source material is preferably, but not necessarily, fed into the ALD reactor after each metal precursor pulse, so that a purge gas pulse separates the oxygen precursor pulse from the metal precursor pulse.
  • lead titanate thin films can be used in pyroelectric infrared sensors, electro-optic devices, and in insulator layers of metal-insulator- semiconductor (MIS) or metal-insulator-metal (MIM) memory cell structures.
  • MIS metal-insulator- semiconductor
  • MIM metal-insulator-metal
  • Example 1 illustrates the invention.
  • FIG. 2 shows an example of a process sequence that can be used for depositing a multimetal oxide (e.g. PbTiO 3 ) thin film.
  • a multimetal oxide e.g. PbTiO 3
  • the control program stored in a computer memory and executed by a CPU comprises nested pulsing cycle routines with programmable global 234 and local pulsing cycle counters 214, 228.
  • Global pulsing cycle counter 234 takes care of the predetermined total thin film thickness.
  • Each local pulsing cycle counter 214, 228 takes care of the predetermined thickness of the sublayers, e.g. binary metal oxides, that form the thin film.
  • a thin film may consist of clearly distinguishable sublayers that have different phases, such as chemical composition or crystallinity, when compared to each other. This kind of film is called as a nanolaminate.
  • Deposited sublayers may also be so thin, in the order of a molecular layer, that they are thoroughly mixed during the deposition process or during post annealing, so that the film consist of a single homogeneous ternary (e.g. PbTiO 3 ), quaternary (e.g. Pb(Zr 5 Ti)O 3 ) or even more complicated solid compound.
  • the ALD reaction chamber is preheated to the deposition temperature to improve the throughput of the system.
  • a substrate is loaded 202 in the reaction space of a single wafer reactor or several substrates are loaded in the reaction space of a batch reactor.
  • the pressure of the reaction space is adjusted with a vacuum generator, e.g. a vacuum pump, and flowing inactive gas so that the substrate(s) are exposed to inactive gas flow 204.
  • Each pulsing cycle consists of four basic steps: precursor 1 pulse / purge / precursor 2 pulse / purge.
  • the first pulsing cycle is used for growing lead oxide layer on the surface.
  • Lead precursor vapor is pulsed to the reaction space 206.
  • Pb precursor molecules chemisorb on heated surfaces of the reaction space including the substrate until available active surface sites have been consumed and the chemisorption process self- terminates. Residual Pb precursor molecules and gaseous by-products originating from the surface reactions are removed from the reaction space during the purge step 208. Then the substrate is exposed to oxygen precursor 210.
  • Oxygen precursor molecules react with the chemisorbed Pb precursor molecules so that the ligands attached to lead are removed or burned away and oxygen forms a chemical bond with Pb on the surface.
  • Residual oxygen precursor molecules and gaseous by-products, such as CO 2 and H 2 O, originating from the surface reactions are removed from the reaction space during the purge step 212.
  • the surface reactions with the oxygen precursor leave hydroxyl (-OH) groups on the surface. These -OH groups serve as active sites for the chemisorption of the gas phase molecules of the subsequent metal precursor pulse. As a result, no more than a molecular layer of lead oxide is formed on the substrate surface.
  • the thickness increase of the thin film per pulsing cycle is typically much less than a molecular layer of PbO because of the bulky ligands attached to the chemisorbed Pb precursor molecule.
  • Pulsing cycle counter is then checked 214 by the control program. If the predetermined thickness of the PbO sublayer, corresponding to specified number of pulsing cycles, is not yet reached, the first pulsing cycle is repeated 216 as many times as is needed. If the PbO sublayer is thick enough, the control program proceeds 218 to the second pulsing cycle.
  • the second pulsing cycle is used for adding a second metal, e.g. titanium Ti, in the form of metal oxide, e.g. titanium dioxide TiO 2 , to the growing thin film, e.g. lead titanate PbTiO 3 .
  • a second metal precursor is pulsed to the reaction space 220.
  • the molecules of the second metal precursor chemisorb on the substrate surface until available active surface sites have been consumed and the chemisorption process self-terminates. Residual second metal precursor molecules and gaseous by-products originating from the surface reactions are removed from the reaction space during the purge step 222. Then, the substrate is exposed to oxygen precursor 224.
  • Oxygen precursor molecules react with the chemisorbed second metal precursor molecules so that the ligands attached to the second metal are removed or burned away and oxygen forms a chemical bond with the second metal atoms on the surface.
  • Residual oxygen precursor molecules and gaseous by ⁇ products, such as CO 2 and H 2 O, originating from the surface reactions are removed from the reaction space during the purge step 226.
  • no more than a molecular layer of second metal oxide is formed on the substrate surface.
  • the thickness increase of the thin film per pulsing cycle is typically clearly less than a molecular layer of the second metal oxide because of the more or less bulky ligands attached to the chemisorbed second metal precursor molecule.
  • local pulsing cycle counter is checked 228 by the control program. If the predetermined thickness of the second metal oxide sublayer, corresponding to specified number of pulsing cycles, is not yet reached, the second pulsing cycle is repeated 230 as many times as is needed. If the second metal oxide sublayer is thick enough, the control program proceeds 232 to the global pulsing cycle counter 234 for checking whether or not the desired total thin film thickness has been reached. If the thin film is not thick enough, the first and the second pulsing cycles are repeated 236. If the film is thick enough, the process control exits 238 the global pulsing cycle loop and the handling of the substrate continues 240, e.g., with annealing, another thin film deposition process or patterning process steps.
  • the growth rate of lead oxide is usually smaller than the growth rate of the second metal oxide.
  • the number of the repeated first pulsing cycles is typically larger than the number of the repeated second pulsing cycles.
  • the ratio of the first pulsing cycles (PbO growth) to the second pulsing cycles (TiO 2 growth) is preferably in the order of 10:1 - 30:1 depending on the deposition temperature and choice of precursors.
  • the first pulsing cycle is used for depositing the second metal oxide (e.g. TiO 2 ) and the second pulsing cycle is used for depositing the lead oxide.
  • the ratio of the first pulsing cycles (TiO 2 growth) to the second pulsing cycles (PbO growth) is now preferably in the order of 1:10 - 1:30, again depending on the deposition temperature and choice of precursors.
  • Nitrogen >99.999 %) was obtained from a nitrogen generator (Nitrox UHPN 3000-1). Ozone generated from oxygen (purity >99.999%) in an ozone generator (Fischer model 502) and water vaporized in a cylinder kept at 30 0 C were used as oxygen sources for Ph 4 Pb and Ti(O 1 Pr) 4 , respectively. The size of the Si(IOO) (Okmetic, Finland) substrates used was 5x10 cm 2 .
  • the ratio of binary oxide layers was altered by changing the relative number of the Ph 4 PbZO 3 and Ti(O 1 Pr) 4 TH 2 O pulses.
  • the slash character denotes alternating sequential pulsing carried out according to the ALD method.
  • the films were deposited by applying a plurality of lead oxide cycles followed by one titanium oxide cycle and then repeating that sequence. Typically, the number of lead oxide cycles was varied between 5 and 50.
  • the total number of PbO/TiO 2 layers was varied in order to control the total film thickness.
  • Thicknesses of the deposited PbTiO 3 films were evaluated by Hitachi U- 2000 spectrometer using the wavelength region 190-1100 nm. Pb and Ti contents were measured using Philips PW 1480 X-ray fluorescence spectrometer equipped with a Rh X-ray tube.
  • TOF-ERDA Time-of-Flight Elastic Recoil Detection Analysis
  • the film crystallinity and preferred orientations were studied by X-ray diffraction (Philips MPD 1880) using Cu K ⁇ radiation. Selected samples were annealed in an RTA oven (PEO 601, ATV Technologie GmbH, Germany) in N 2 or O 2 (>99.999%) atmosphere at 500-900 0 C for 10 minutes at atmospheric pressure. The heating rate of 20 °C/min and cooling rate of 25 °C/min were used. Surface morphologies of selected samples were studied with an atomic force microscope (AFM) AutoProbe CP (Park Scientific Instruments/Veeco) operated in the intermittent-contact mode using UltralevelsTM (Veeco) silicon-cantilevers. Roughness was calculated as root-mean-square (rms) values.
  • AFM atomic force microscope
  • AutoProbe CP Park Scientific Instruments/Veeco
  • UltralevelsTM UltralevelsTM
  • the growth rate of PbO thin films was found to be 0.13 A/cycle at 250 °C and 0.10 A/cycle at 300 0 C when using 1 - 1.5 s pulsing times for Ph 4 Pb.
  • a pulse time of 1.5 s for Ph 4 Pb was used when depositing PbTiO 3 . Pulsing times were 2 s for ozone, 0.6 - 0.8 s for titanium isopropoxide and 1 s for water.
  • XRF measurements showed that the Ti/Pb atomic ratio in films was dependent on the relative amount of the titanium pulses as seen in Fig. 6.
  • the XRF results were calibrated by plotting the XRF Ti/Pb-ratio against the Ti/Pb-ratio measured by RBS. Results were in good congruency with each other. Stoichiometric films were obtained at 250 0 C with a Ti:Pb pulsing ratio of 1:10 and at 300 0 C with a pulsing ratio of 1:28.
  • Lead oxide thin films were grown by ALD using tetraphenyl lead Ph 4 Pb as a lead precursor.
  • the evaporation temperature was 165 to 170 0 C.
  • the effect of the deposition temperature on the growth rate was studied over a temperature range of 185 to 400 0 C for the Ph 4 PWO 3 process.
  • Pulsing times for Ph 4 Pb were 1.0 to 3.0 s.
  • the ozone pulse was varied in the range of 1.0 to 3.0 s and the nitrogen pulses between 1.0 and 2.5 s.
  • the lead-to-oxygen ratio was close to 0.7. Impurities levels were 0.5 at-% for carbon and less than 0.1 at-% for hydrogen at films deposited at 250 °C.
  • FIG. 3 shows the growth rate of PbO 2 thin firms as a function of the deposition temperature. Tetraphenyllead Ph 4 Pb was used as the lead precursor and ozone O 3 was used as the oxygen precursor. The pulsing times for Ph 4 Pb and O 3 were 1.0 s and 2.0 s, respectively. Constant growth rate Of PbO 2 was obtained when the substrate temperature was in the range of 200 - 250 0 C.
  • an insert 300 shows the growth rate of PbO 2 using Pb(thd) 2 and O 3 as precursors. The pulsing times for Pb(thd) 2 and O 3 were 1.0 s and 1.5 s, respectively. The substrate temperature affected rather strongly the growth rate Of PbO 2 .
  • FIG. 4 shows XRD patterns of PbO 2 films deposited from Ph 4 Pb at 250 0 C (a) and from Pb(thd) 2 at 150 0 C (b).
  • the thickness for (a) was 70 nm and for (b) was 170 nm.
  • Diffraction peeks were identified according to JCPDS cards 25-447 and 37-517.
  • FIG. 5 shows the growth rate of lead oxide thin films deposited at 250 0 C and 300 0 C using Ph 4 Pb as the Pb precursor with different Ph 4 Pb vapour pulse lengths. Pulsing time for O 3 was 2.0 s and purging time 1.0-2.0 s depending on the precursor pulsing time.
  • FIG. 6 shows the ratio of titanium and lead content in Pb-Ti-O films deposited at 250 0 C and 300 0 C on Si(IOO) as a function of the precursor pulsing ratio.
  • the film composition was measured by X-ray Fluorescence (XRF) and independently verified by Time-of-Flight Elastic Recoil Detection Analysis (TOF ERDA).
  • XRF X-ray Fluorescence
  • TOF ERDA Time-of-Flight Elastic Recoil Detection Analysis
  • FIG. 7 shows X-ray Diffraction (XRD) patterns Of PbTiO 3 films annealed at 800 0 C (a), 900 0 C (b), and 1000 0 C (c) in nitrogen N 2 atmosphere for 10 min.
  • XRD X-ray Diffraction
  • Lead magnesium niobate thin containing thin films can be deposited by using lead precursors of the present invention, such as Ph 4 Pb or Et 4 Pb, magnesium precursor, such as magnesium cyclopentadienyl Mg(Cp) 2 or Mg(IM) 2 , niobium precursor, such as niobium ethoxide Nb(OEt) 5 or other alkoxides, niobium chloride NbCl 5 or fluoride NbF 5 and oxygen precursor, such as water or ozone.
  • lead precursors of the present invention such as Ph 4 Pb or Et 4 Pb
  • magnesium precursor such as magnesium cyclopentadienyl Mg(Cp) 2 or Mg(IM) 2
  • niobium precursor such as niobium ethoxide Nb(OEt) 5 or other alkoxides
  • niobium chloride NbCl 5 or fluoride NbF 5 oxygen precursor, such as water or ozone.
  • Lead titanate and/or barium titanate to the lead magnesium niobate can be performed by adjusting the cycle number of each sub-process. As an example, first one cycle of lead magnesium niobate is deposited and then one cycle of lead titanate is deposited. Further, one cycle of barium titanate can be deposited if desired.
  • Deposition of lead magnesium containing thin films can be performed several ways. As an example one generalized way is presented for deposition niobium containing lead oxide films:
  • Lead precursor such as Ph 4 Pb or Et 4 Pb
  • Lead precursor is introduced to the substrate on a reaction space. After the lead precursor is introduced to the reaction space it will be purged with or without purge gas.
  • oxygen containing precursor such as water or ozone
  • niobium containing precursor such as niobium ethoxide
  • oxygen containing precursor such as water or ozone
  • magnesium containing precursor such as bis(cyclopentadienyl)magnesium or bis(2,2,6,6-tetramethyl-3,5- heptanedionato)magnesium
  • PbMgNbO 3 is deposited on the substrate. This sub-cycle is repeated, if desired, as many times as necessary to form a film with desired composition and/or structure. Inside this sub-cycle the amount of metals to be deposited in the film can be adjusted just by skipping desired amount of one or more of the metal containing precursor pulses and the following oxygen containing precursor pulse.
  • Lead precursor such as Ph 4 Pb or Et 4 Pb
  • the reaction space will be purged with or without purge gas.
  • oxygen containing precursor such as water or ozone
  • titanium containing precursor such as titanium methoxide or titanium isopropoxide
  • oxygen containing precursor is introduced to the substrate on reaction space.
  • the reaction space After introducing the oxygen containing precursor the reaction space will be purged with or without purge gas. After purge step, one molecular layer of PbTiO 3 is deposited on the substrate.
  • This sub-cycle is repeated, if desired, as many times as necessary to form a film with desired composition and/or structure. Inside this sub-cycle the amount of metals to be deposited in the film can be adjusted just by skipping desired amount of one of the metal containing precursor pulses and the following oxygen containing precursor pulse.
  • Barium precursor such as THF adduct bis ⁇ entametftylcyclopentadienyl)barium
  • Ba(C 5 (CH 3 )5)THF x where x is 0-2, is introduced to the substrate on a reaction space.
  • the reaction space will be purged with or without purge gas.
  • oxygen containing precursor such as water or ozone
  • titanium containing precursor such as titanium methoxide or titanium isopropoxide
  • oxygen containing precursor such as water or ozone
  • the reaction space will be purged with or without purge gas.
  • one molecular layer of BaTiO 3 is deposited on the substrate. This sub-cycle is repeated, if desired, as many times as necessary to form a film with desired composition and/or structure. Inside this sub-cycle the amount of metals to be deposited in the film can be adjusted just by skipping desired amount of one of the metal containing precursor pulses and the following oxygen containing precursor pulse.
  • These three sub-cycles can be repeated, if desired, as many times as necessary to form a film with desired composition and/or structure.
  • the amount of sub-cycles can be adjusted to match the desired composition/structure of the film by skipping skipping desired amount of sub-cycles.
  • the order of the sub-cycles can also be changed.
  • Annealing at high temperature and desired atmospehere can be performed for crystallization after the deposition of lead magnesium niobate thin containing thin films.
  • lead oxide films were deposited at ALD conditions using as a precursor for lead an organometallic compound, in which the ligand is attached to the metal atom via oxygen-metal bonds.
  • the evaporation temperature for bis(2,2,6,6-tetramethyl-3,5-heptanedionato)lead Pb(thd) 2 was 110 - 115 0 C.
  • the effect of the deposition temperature on the growth rate was studied over a temperature range of 150 to 300 °C.
  • Precursor pulsing and purging times were also studied in order to optimise the deposition process. Pulsing times studied for Pb(thd) 2 were 1.0 - 3.0 s. Ozone pulse was varied between 1.0 and 3.0 s and the purging nitrogen pulse was varied in the range of 1.0 to 2.5 s.
  • the growth rate increased with increasing deposition temperature. Also a clear thickness profile and dim and black film surface were observed at 250 0 C and above.
  • the growth rates for the Pb(thd)2 process were 1.0 to 1.5 A/cycle at temperatures below 200 °C and it increased up to 7.6 A/cycle, when the deposition temperature reached 300 0 C .
  • Pulsing times for Pb(thd) 2 were examined at 150 0 C. At 1.0 s pulsing times, the films were smooth, and no differences were observed with longer pulsing times, indicating ALD type growth. The Pb(thd) 2 pulse was then kept constant at 1.0 s and the ozone pulse was fixed between 1.0 and 3.0 s.
  • the thin films deposited from Pb(thd) 2 were all crystalline regardless of the deposition temperatures. Below 200 0 C the films were polycrystalline with orthorhombic (O) and tetragonal (T) lead dioxide (PbO 2 ) phases. The most intense reflection at 150 0 C was tetragonal (110), whereas at 200 0 C, the most intense reflection was orthorhombic (111).
  • the lead-to-oxygen ratio was close to 0.7.
  • the impurity levels were 1.1 at-% for carbon and 0.1 at-% for hydrogen for films deposited at 150 0 C.

Abstract

A process for producing lead containing oxide thin films by Atomic Layer Deposition, comprising using a metal-organic lead compound, having organic ligands bonded to a lead atom by carbon-lead bonds, as a source material for the lead oxide. Stoichiometric PbTiO3 thin films with excellent uniformity can be deposited on substrates by ALD growth using, for example, Ph4Pb, O3, Ti(OiPr)4 and H2O as precursors at 250 and 300 °C.

Description

METHOD OF DEPOSITING LEAD CONTAINING OXIDES FILMS
Background of the Invention
Field of the Invention
The presents invention relates generally to the field of microelectronics and in particular to methods of producing lead containing oxide thin films by gas phase deposition methods and, more particular, by atomic layer deposition (ALD), and to lead containing oxide thin films.
Background of the Invention
The lead titanate (PT) family consists of a large range of solid compounds, such as PZT (lead zirconate titanate), PLT (lead lanthanum titanate) and PLZT (lead lanthanum zirconate titanate). By adding dopants, e.g. lanthanum and zirconium, it is possible to improve the properties of lead titanate (PbTiO3) for specific thin film applications, e.g. ferroelectric memories, pyroelectric infrared sensors, piezoelectric applications, electro- optic devices and insulator in metal-insulator- semiconductor (MIS) and metal-insulator- metal (MIM) capacitors. Lead niobates (PbNbOx), such as lead magnesium niobate (PMN) and lead zinc niobate (PZN), have also similar properties and possibilities to similar applications than lead titanates. Properties, such as dielectric constant, can be increased by mixing, for example, lead magnesium niobate (PbMgNbO3) with lead titanates to form PMN-PT material. Further to this, PMN-PT material can be mixed with barium titanate (BT) to form PMN-PT-BT material.
The perovskite-type PbTiO3 has a high Curie temperature of 490 0C, a relatively low permittivity (compared to other lead titanate family compounds) and a large pyroelectric coefficient. Lead titanate thin films have basically the same physical properties as the bulk material but in memory applications they have low operating voltage and high switching speed. The material PbMgNbO3 + PbTiO3 (PMN-PT) has a very high k-value of about 22600. The material PbMgNbO3 itself has also a high k-value of about 7000. Thin films of above mentioned materials, such as PT, PZT, PMN, PMN-PT, have been prepared by different chemical and physical methods. Metal-organic chemical vapor deposition (MOCVD), with all its different variations, such as laser induced-MOCVD, plasma induced-MOCVD and ion beam induced-MOCVD, is the most used deposition method. Ih addition to conventional CVD methods, the so-called "improved MOCVD" method has been used to deposit a- and c-axis-oriented thin films. In such a method, the metal precursor vapors have been alternately introduced into the reactor together with the oxygen source. Other chemical and physical deposition methods used for preparing thin films of PbTiO3 include rf magnetron sputtering, pulsed laser ablation, the sol-gel method, spin-coating, chemical solution deposition and hybrid chemical methods.
For practical applications, the lead containing oxide thin films have to meet stringent quality demands. Thus, the films have to be defect-free and they must have low surface roughness. Also the interface between the ferroelectric and the substrate is important. To avoid undesirable interfacial reactions during the semiconductor process, a low deposition temperature is preferred.
Atomic Layer Deposition (ALD - or, as it was earlier called, "Atomic Layer Epitaxy", abbreviated ALE) is a well-known method for growing high-quality thin films on substrates. ALD method is based on sequential self- saturating surface reactions resulting in thin films that have low impurity content and uniform physical properties including film thickness. A reference is made to the following two publications.
The principles of ALD type processes have been presented by the inventor of the ALD technology, Dr. T. Suntola, e.g., in Handbook of Crystal Growth 3, Thin Films and Epitaxy, Part B: Growth Mechanisms and Dynamics, Chapter 14, "Atomic Layer Epitaxy", pp. 601-663, Elsevier Science B.V. 1994, the disclosure of which is incorporated herein by reference.
Extensive selections of ALD precursors and ALD-grown materials have been presented by Prof. M. Ritala and Prof. M. Leskela in a recent review article, Handbook of Thin Film Materials, Vol. 1: Deposition and Processing of Thin Films, Chapter 2 "Atomic Layer Deposition", pp. 103-159, Academic Press 2002. However, the known methods of depositing lead containing oxide thin films are not compatible with ALD processes. Further, the lead containing oxygen thin films deposited according to known methods do not provide devices with satisfactory performance levels.
With regard to the state of the art and to the various problems encountered, it should also be noted that lead oxide exists in many different forms because lead can adopt a valence state of either +2 or +4. Lead oxides have also many different crystal forms. Consequently, it is difficult to deposit lead oxide thin films containing only one oxide form with a certain crystal form. Earlier studies have shown that lead oxide thin films deposited by metal organic chemical vapor deposition (MOCVD) contain both lead oxide and oxygen rich form of lead dioxide.
Therefore, there is a need for a repeatable and controlled method of depositing uniform thin films that contain lead oxide.
Summary of the Invention
It is an object of the present invention to eliminate the problems related to the known methods and to provide a novel method of manufacturing lead oxide containing thin films, such as high performance lead titanate (PbTiO3) or lead magnesium niobate (PbMgNbO3) for thin film applications.
It is another object to provide a method of producing multicomponent lead oxide films.
These and other objects, together with the advantages thereof over known processes and products, are achieved by the present invention as hereinafter described and claimed.
According to the invention, binary lead oxides and ternary, quaternary and more complicated metal oxides containing lead oxide can be grown by the ALD process from metal-organic lead precursors that contain organic ligands bonded to the lead atom of the compound by carbon-metal bonds. Surprisingly, it has been found that traditional organo metallic precursors in which the metal is bonded to the organic residues via oxygen atoms do not give rise to genuine ALD growth, or ALD growth is achieved only within narrow temperature ranges, and films produced exhibit high levels of impurities. By contrast, the present lead precursors result in ALD growth within various (broad) temperature ranges and the thin films have very low concentrations of residues from the ligands.
The present invention also provides a process for forming lead containing multicomponent oxide thin films by Atomic Layer Deposition on a substrate in a reaction space.
More specifically, the method of producing thin firms according to the present invention is mainly characterized by what is stated in the characterizing part of claim 1.
The method for producing multicomponent lead oxide firms is mainly characterized by what is stated in the characterizing part of claim 23.
The present invention provides considerable advantages. Thus, stoichiometric PbTiO3 thin films with excellent uniformity can be deposited on substrates by ALD growth using, for example, Ph4Pb, O3, Ti(O1Pr)4 and H2O as precursors at substrate temperatures of 250 and 300 °C. Also a stoichiometric PbMgNbO3 thin films with excellent uniformity can be deposited on substrates by ALD growth using, for example, Ph4Pb, Mg(Cp)2, Nb(OEt)5 and O3 and/or H2O as precursors at substrate temperatures of 250 and 300 0C. At constant deposition temperatures and pulsing ratios, using the present precursors, the film thickness of PbTiO3 films has been found to be linearly dependent on the number of deposition cycles, indicating genuine ALD growth.
As will appear from the examples below, thin films produced by the present invention typically contain only small amounts of hydrogen and carbon impurities according to Time-of-Flight Elastic Recoil Detection Analysis (TOF-ERDA).
Lead titanate films are amorphous after deposition, but crystalline PbTiO3 thin films can be obtained according to the process of the invention by annealing the amorphous films at temperatures above 500 0C, e.g. 600 0C, or more. By converting the amorphous films into crystalline firms, higher dielectric constants are obtained. Next the invention will be discussed more closely with the aid of a detailed description and a working example.
Brief Description of the Drawings
FIG. 1 shows a structural and a shaded ball drawing of a tetraphenyllead Ph4Pb molecule.
FIG. 2 shows an example of a process sequence used for depositing a multimetal oxide thin film.
FIG. 3 shows the growth rate Of PbO2 thin films as a function of deposition temperature. FIG. 4 shows x-ray diffraction diagrams of PbO2 films deposited from selected Pb precursors.
FIG. 5 shows the deposition rate of lead oxide thin films at selected temperatures deposited from Ph4Pb with different material pulse lengths.
FIG. 6 shows the effect of Ti / Pb precursor pulsing ratio on the titanium and lead content in Pb-Ti-O films deposited at selected temperatures.
FIG. 7 shows the effect of annealing on PbTiO3 firms revealed by x-ray diffraction diagrams.
Detailed Description of the Invention
As known in the art, there are various variations of the basic ALD method, including PEALD (plasma enhanced ALD) in which plasma is used for activating reactants. Conventional ALD or thermal ALD refers to an ALD method where plasma is not used but where the substrate temperature is high enough for overcoming the energy barrier (activation energy) during collisions between the chemisorbed species on the surface and reactant molecules in the gas phase so that up to an atomic (elemental) or a molecular (compound) layer of thin film grows on the substrate surface during each ALD pulsing sequence. For the purpose of the present invention, ALD covers both PEALD and thermal ALD.
Definitions
In context of the present invention, "an ALD type process" generally refers to a process for producing thin films over a substrate, in which process a solid thin film is formed molecular layer by molecular layer due to self- saturating chemical reactions on heated surfaces. Ih the process, gaseous reactants, i.e. precursors, are conducted into a reaction space of an ALD type of a reactor and contacted with a substrate located in the chamber to provide a surface reaction. The pressure and the temperature of the reaction space are adjusted to a range where physisorption (i.e. condensation of gases) and thermal decomposition of the precursors are avoided. Consequently, only up to one monolayer (i.e. an atomic layer or a molecular layer) of material is deposited at a time during each pulsing cycle. The actual growth rate of the thin film, which is typically presented as A/pulsing cycle, depends, for example, on the number of available reactive surface sites on the heated surface and bulkiness of the chemisorbing molecules. Gas phase reactions between precursors and any undesired reactions of by-products are inhibited because material pulses are separated from each other by time and the reaction space is purged with an inactive gas (e.g. nitrogen or argon) or evacuated between material pulses to remove surplus gaseous reactants and reaction by-products from the chamber.
In context of the present application "a reaction space" designates generally a reactor or a reaction chamber in which the conditions can be adjusted so that deposition of a thin film is possible.
In context of the present application, "an ALD type reactor" means a reactor where the reaction space is in fluid communication with an inactive gas source and at least one, preferably at least two precursor sources that can be pulsed, i.e. the precursor vapour pushed from the precursor source can be introduced as a gas pulse into the reaction space, the reaction space is in fluid communication with a vacuum generator (e.g. a vacuum pump), and the temperature and pressure of the reaction space and the flow rates of gases can be adjusted to a range that makes it possible to grow thin films by ALD type processes.
In context of the present application, "rare earths" means elements of the group 3 (scandium Sc, yttrium Y, lanthanum La) and lanthanide series (cerium Ce, praseodymium Pr, neodymium Nd, samarium Sm, europium Eu, gadolinium Gd, terbium Tb, dysprosium Dy, holmium Ho, erbium Er, thulium Tm, ytterbium Yb and lutetium Lu) of the periodic table of elements. "Source material" and "precursor" are used interchangeably in the present application to designate a volatile or gaseous compound, which can be used as a starting compound for the corresponding metal oxide of the thin film.
"Multicomponent oxide" films stands for films comprising oxides of at least 2 metal species, typically 2 to 4 metal species. Such films may comprise oxides such as Pb(Zr, Ti)O3 or Pb(Mg, Nb)O3, but they may also be formed by two or more different oxides, such as multicomponent oxide thin film comprising both Pb(Mg, Nb)O3 and PbTiO3. There may even be three oxide components in the multicomponent oxide thin film, such as Pb(Mg, Nb)O3, PbTiO3 and BaTiO3.
Source materials
Lead precursors According to the present invention, metal-organic lead precursors containing organic ligands which are bonded to the lead atom via carbon-lead bonds are used as source materials in the production of thin films in ALD reactors. The metal-organic lead compound has 2 or 4 alkyl ligands or ligands comprising aromatic groups. In particular, the metal-organic lead compound has the formula
L1L2L3L4Pb
wherein each L1, L2, L3 and L4 is independently selected from
- linear or branched C1-C20 alkyl or alkenyl groups, - halogenated alkyl or alkenyl groups, wherein at least one hydrogen atom is replaced with fluorine, chlorine, bromine or iodine atom,
- carbocyclic groups, such as aryl, preferably phenyl, tolyl and xylyl, alkylaryl groups including benzyl, cyclic dienes, halogenated carbocyclic groups, and
- heterocyclic groups (provided that these are bonded to the metal via a carbon atom.
According to a preferred embodiment, the precursors contain four organic ligands selected from the group of optionally substituted, linear, branched or cyclic alkyl groups or aryl groups. "Alkyl" stands, for example, for an alkyl group, selected from methyl, ethyl, n- and i-propyl, and n-, sec- and t-butyl. In each ligand, and in different ligands, the alkyl groups may be the same or different. Above, the chlorinated alkyl and alkenyl groups are mentioned. Other substituents are also possible, such as hydroxyl, carboxy, thio, silyl and amino groups.
Specific examples of the present novel precursors are tetraphenyl lead and tetraethyl lead.
Turning now to the drawings, it can be noted that FIG. 1 depicts a structural 100 and a shaded ball drawing 110 of a tetraphenyllead Ph4Pb molecule. The molecules consists of lead 102, carbon 104 and hydrogen 106 atoms. It can be seen that the Pb atom 102 in the center of the Ph4Pb molecule is shielded with phenyl C6Hs ligands resulting in good thermal stability of the precursor. It is possible to further improve the shielding effect of the ligands on the center Pb atom and to increase the thermal stability of the Pb precursor by modifying the phenyl ligands so that there are, e.g., alkyl group(s) attached to the carbon ring instead of hydrogen atom(s).
Second metal precursors
Second metal source material needed for ternary or higher metal oxides can be a metal compound or a complex metal compound comprising two or several metals. The metals are typically selected from the group of volatile or gaseous compounds of transition metals and main group metals according to the system recommended by IUPAC in the periodic table of elements, i.e., elements of groups comprising
- 1 (Li, Na, K, Rb, Cs);
- 2 (Mg, Ca, Sr, Ba); - 3 (Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu);
- 4 (Ti5 Zr5 Hf);
- 5 (V5 Nb5 Ta);
- 6 (Cr5 Mo5 W);
- 7 (Mn5 Re); - 8 (Fe5 Ru5 Os);
- 9 (Co5 Rh5 Ir);
- 10 (Ni, Pd, Pt);
- 11 (Cu, Ag, Au);
- 12 (Zn, Cd, Hg); - 13 (Al, Ga, In, Tl);
- 14 (Si, Ge, Sn); and/or
- 15 (Sb, Bi).
Since the properties of each metal compound vary, the suitability of each metal compound for the use in the process of the present invention has to be considered. The properties of the compounds are found, e.g., in N. N. Greenwood and A. Earnshaw, Chemistry of the Elements, 1st edition, Pergamon Press, 1986.
Typically, suitable second metal source materials are preferably selected from the group comprising
- halides, preferably fluorides, chlorides, bromides or iodides;
- metal organic compounds, preferably alkoxides (cf. the titanium isopropoxide of the Example 1 and niobium ethoxide); - alkylamino;
- cyclopentadienyl, alkyl derivatives of cyclopentadienyl;
- dithiocarbamate;
- amidinate;
- beta-ketoiminate; - beta-diketiminate; and
- beta-diketonate compounds of the desired metal(s).
Double metal precursors, i.e. molecules containing two metals in a discrete stoichiometric ratio, may also be used. Examples of double metal precursors include double metal alkoxides that have been presented, e.g., in a chemical catalogue from Gelest, Inc. (Edited by B. Arkles, Gelest, Inc. 1995, pp. 344-346).
Oxygen precursors
The oxygen source material is preferably selected from the group comprising
- water; - oxygen;
- hydrogen peroxide H2O2, aqueous solutions of hydrogen peroxide;
- ozone O3;
- oxides of nitrogen including NO2, NO, N2O;
- halide-oxygen compounds; - peracids -C(=O)-O-OH;
- alcohols, such as methanol, ethanol, propanol and isopropanol;
- alkoxides;
- oxygen-containing radicals, such as O* and HO*, wherein * denotes an unpaired electron; and
- mixtures thereof.
Ozone gas is often diluted with oxygen gas due to the ozone manufacturing methods. The oxygen precursor vapor is optionally diluted with inactive gas.
Process conditions
The reaction temperature can vary depending on the evaporation temperature and the decomposition temperature of the precursor. A typical range is represented by about 150 to 400 °C, in particular about 180 to 380 °C. Based on the results obtained for crystallization, it is particularly preferred to grow lead titanate films from tetraphenyl lead at temperatures below 300 0C, typically about 200 to 290 0C, e.g. about 250 °C, to achieve crystallization of the films at modestly high annealing temperatures.
According to the invention, gas phase pulses of the evaporated metal-organic lead compound mixed with inactive carrier gas or without the inactive carrier gas are introduced into an ALD reactor, in which they are contacted with a suitable substrate. The deposition can be carried out at normal pressure, but it is preferred to operate the method at reduced pressure. The pressure in the reactor is typically 0.01 - 20 mbar, preferably 0.1 - 5 mbar.
The substrate temperature has to be low enough to keep the bonds between thin film atoms intact and to prevent thermal decomposition of the gaseous reactants. On the other hand, the substrate temperature has to be high enough to keep the source materials in gaseous phase, i.e., condensation of the gaseous reactants must be avoided. Further, the temperature must be sufficiently high to provide the activation energy for the surface reaction.
At these conditions, the amount of reactants bound to the surface will be determined by the surface. This phenomenon is called "serf-saturation".
For further details on the operation of a typical ALD process, reference is made to the documents cited above and to Example 1 below. The substrate can be of various types. Examples include silicon, silica, coated silicon, germanium, silicon-germanium alloys, copper metal, noble and platinum metals group including silver, gold, platinum, palladium, rhodium, iridium and ruthenium, various nitrides, such as transition metal nitrides, e.g. tantalum nitride TaN, various oxides, such as platinum group metal oxides, e.g. ruthenium dioxide RuO2, various carbides, such as transition metal carbides, e.g. tungsten carbide WC, transition metal nitride carbides, e.g. tungsten nitride carbide WNxCy and dielectric surfaces, such as high-k oxides serving as interfacial layers, e.g. Al2O3 or La2O3 being an example of rare earth oxides.
Similarly, surface consisting of lead oxide or ternary, quaternary or more complicated metal oxide containing lead oxide, can serve as a substrate surface for further deposition of thin firms including noble and platinum metals group and other materials presented in the previous paragraph. The resulting multilayer sandwich structure is utilized for example in metal-insulator-metal (MM) devices.
Conventionally, the preceding thin film layer deposited will form the substrate surface for the next thin film.
In order to convert the adsorbed (chemisorbed) lead precursor into lead oxide, the reactor is evacuated and/or purged with a purge gas comprising an inactive gas, and then a next gas phase pulse of an oxygen source material, such as ozone O3, is introduced into the reactor. The oxygen precursor vapor is optionally diluted with inactive gas.
By alternating the reactions of the lead precursor and the oxygen source material, a lead containing oxide thin film can be deposited. Typically, a growth rate of about 0.10 to 0.20 A/cycle is achieved.
In order to produce multicomponent oxide films, a second metal source material can be introduced at ALD conditions.
In particular, a multicomponent oxide film consists essentially of Pb oxide and of an oxide preferably selected from Bi, Ca, Ba, Sr, Cu, Ti, Ta, Zr, Hf, V, Nb, Zn, Cr, W, Mo, Al, rare earths (e.g. La) and/or Si oxides and, thus, the corresponding gaseous or volatile metal compounds are preferably used in the method of the present invention. The second (third etc.) metal source material can be oxidized using the same or another oxygen source material as for the lead precursor.
Titanium, lanthanum and zirconium are particularly interesting as sources of a second and/or third and/or fourth metal in ternary and other multicomponent lead containing . oxides. Niobium, magnesium and zinc are particularly interesting as sources of a second and/or third and/or fourth metal in ternary and other multicomponent lead containing oxides. Multicomponent Pb/Ti and Pb/Ti and La and/or Zr or multicomponent Pb/Nb and Pb/Nb and Mg oxides are potentially valuable as high-k dielectric material.
According to one preferred embodiment, multicomponent films are produced by feeding alternating pulses of the various metal precursors (followed by the above mentioned oxygen source pulses) into an ALD reactor. This embodiment based on "mixing cycles" will give rise to a ferroelectric phase after deposition. Typically, the ratio of cycles consisting of lead containing precursor followed by oxygen source pulses to cycles consisting of a second metal source followed by the corresponding oxygen source pulses is about 50:1...1:50, preferably about 40:1 to 1:40, in particular about 35:1...1:1 (metal to metal, based on moles).
In theory, a stoichiometric oxide ABO3, wherein A and B denote two different metals, can be obtained simply by pulsing the two metal precursors and corresponding oxygen sources alternately and the growth rate of the ternary oxide can be predicted by summing the growth rates of the constituent oxides. In practice, however, both assumptions often fail due to the different reactivities of the precursors. The effect of surface chemistry usually causes changes in relative growth rate, which can be determined by comparing the observed firm thickness with the theoretical thickness calculated from the growth rates of binary oxides. According to the present invention, the relative growth rate of PbTiO3 was found to be dependent on the pulsing ratio of precursors and also on the deposition temperature. Maximum relative growth rates were obtained at 250 and 300 0C by using Ti:Pb pulsing ratios 1:15 and 1:50, respectively, being 155 % at 250 0C and 190 % at 300 0C. Another preferred embodiment comprises preparing multicomponent films by depositing laminar layers of each metal oxide and by annealing the laminar layers together at increased temperatures to provide a crystalline phase. In this way, first an amorphous structure is provided and a high dielectric material is obtained by annealing in the presence of oxygen (such as in the presence of air) at temperatures in excess of 500 0C, in particular in excess of 700 °C, in the presence of an oxygen-containing compound (e.g. N2O) or in the presence of an inert gas (e.g. N2 or Ar).
Thus, the polycrystalline tetragonal perovskite PbTiO3 phase (JCPDS Card No 6-452) can be observed by XRD when stoichiometric or lead-rich films deposited at 250 0C are annealed either in nitrogen or oxygen atmosphere for at least 1 minute, preferably for 5 to 60 minutes, typically about 10 minutes, at a temperature in the range of 600 to 900 0C. Annealing in oxygen is a particularly preferred way of crystallizing PbTiO3 for lead oxide films deposited at 250 °C. Films annealed in oxygen are smooth and shiny even after annealing at 900 °C. By contrast, annealing in nitrogen is a preferred embodiment for the films deposited at 300 °C.
In the above embodiments, where a second and further metal precursors are fed into an ALD reactor, a gas phase pulse of an oxygen source material is preferably, but not necessarily, fed into the ALD reactor after each metal precursor pulse, so that a purge gas pulse separates the oxygen precursor pulse from the metal precursor pulse.
The present novel thin film oxide materials will find extensive use in the semiconductor industry applications. In particular lead titanate thin films can be used in pyroelectric infrared sensors, electro-optic devices, and in insulator layers of metal-insulator- semiconductor (MIS) or metal-insulator-metal (MIM) memory cell structures.
The following non-limiting examples illustrate the invention. Example 1:
ALD Processing of lead oxide films
FIG. 2 shows an example of a process sequence that can be used for depositing a multimetal oxide (e.g. PbTiO3) thin film. Throughout of the history of ALD (ALE), nested pulsing cycles have been utilized in the control program for ALD film growth. The control program stored in a computer memory and executed by a CPU comprises nested pulsing cycle routines with programmable global 234 and local pulsing cycle counters 214, 228. Global pulsing cycle counter 234 takes care of the predetermined total thin film thickness. Each local pulsing cycle counter 214, 228 takes care of the predetermined thickness of the sublayers, e.g. binary metal oxides, that form the thin film.
A thin film may consist of clearly distinguishable sublayers that have different phases, such as chemical composition or crystallinity, when compared to each other. This kind of film is called as a nanolaminate. Deposited sublayers may also be so thin, in the order of a molecular layer, that they are thoroughly mixed during the deposition process or during post annealing, so that the film consist of a single homogeneous ternary (e.g. PbTiO3), quaternary (e.g. Pb(Zr5Ti)O3) or even more complicated solid compound.
Typically, the ALD reaction chamber is preheated to the deposition temperature to improve the throughput of the system. A substrate is loaded 202 in the reaction space of a single wafer reactor or several substrates are loaded in the reaction space of a batch reactor. The pressure of the reaction space is adjusted with a vacuum generator, e.g. a vacuum pump, and flowing inactive gas so that the substrate(s) are exposed to inactive gas flow 204.
Each pulsing cycle consists of four basic steps: precursor 1 pulse / purge / precursor 2 pulse / purge. In this example the first pulsing cycle is used for growing lead oxide layer on the surface. Lead precursor vapor is pulsed to the reaction space 206. Pb precursor molecules chemisorb on heated surfaces of the reaction space including the substrate until available active surface sites have been consumed and the chemisorption process self- terminates. Residual Pb precursor molecules and gaseous by-products originating from the surface reactions are removed from the reaction space during the purge step 208. Then the substrate is exposed to oxygen precursor 210. Oxygen precursor molecules react with the chemisorbed Pb precursor molecules so that the ligands attached to lead are removed or burned away and oxygen forms a chemical bond with Pb on the surface. Residual oxygen precursor molecules and gaseous by-products, such as CO2 and H2O, originating from the surface reactions are removed from the reaction space during the purge step 212. Typically, the surface reactions with the oxygen precursor leave hydroxyl (-OH) groups on the surface. These -OH groups serve as active sites for the chemisorption of the gas phase molecules of the subsequent metal precursor pulse. As a result, no more than a molecular layer of lead oxide is formed on the substrate surface. The thickness increase of the thin film per pulsing cycle is typically much less than a molecular layer of PbO because of the bulky ligands attached to the chemisorbed Pb precursor molecule. Pulsing cycle counter is then checked 214 by the control program. If the predetermined thickness of the PbO sublayer, corresponding to specified number of pulsing cycles, is not yet reached, the first pulsing cycle is repeated 216 as many times as is needed. If the PbO sublayer is thick enough, the control program proceeds 218 to the second pulsing cycle.
In this example, the second pulsing cycle is used for adding a second metal, e.g. titanium Ti, in the form of metal oxide, e.g. titanium dioxide TiO2, to the growing thin film, e.g. lead titanate PbTiO3. A second metal precursor is pulsed to the reaction space 220. The molecules of the second metal precursor chemisorb on the substrate surface until available active surface sites have been consumed and the chemisorption process self-terminates. Residual second metal precursor molecules and gaseous by-products originating from the surface reactions are removed from the reaction space during the purge step 222. Then, the substrate is exposed to oxygen precursor 224. Oxygen precursor molecules react with the chemisorbed second metal precursor molecules so that the ligands attached to the second metal are removed or burned away and oxygen forms a chemical bond with the second metal atoms on the surface. Residual oxygen precursor molecules and gaseous by¬ products, such as CO2 and H2O, originating from the surface reactions are removed from the reaction space during the purge step 226. As a result, no more than a molecular layer of second metal oxide is formed on the substrate surface. The thickness increase of the thin film per pulsing cycle is typically clearly less than a molecular layer of the second metal oxide because of the more or less bulky ligands attached to the chemisorbed second metal precursor molecule. Next, local pulsing cycle counter is checked 228 by the control program. If the predetermined thickness of the second metal oxide sublayer, corresponding to specified number of pulsing cycles, is not yet reached, the second pulsing cycle is repeated 230 as many times as is needed. If the second metal oxide sublayer is thick enough, the control program proceeds 232 to the global pulsing cycle counter 234 for checking whether or not the desired total thin film thickness has been reached. If the thin film is not thick enough, the first and the second pulsing cycles are repeated 236. If the film is thick enough, the process control exits 238 the global pulsing cycle loop and the handling of the substrate continues 240, e.g., with annealing, another thin film deposition process or patterning process steps.
The growth rate of lead oxide is usually smaller than the growth rate of the second metal oxide. Thus, the number of the repeated first pulsing cycles is typically larger than the number of the repeated second pulsing cycles. In case of stoichiometric PbTiO3 deposition, the ratio of the first pulsing cycles (PbO growth) to the second pulsing cycles (TiO2 growth) is preferably in the order of 10:1 - 30:1 depending on the deposition temperature and choice of precursors.
It is possible to reverse the order of metal oxides deposition. In that case the first pulsing cycle is used for depositing the second metal oxide (e.g. TiO2) and the second pulsing cycle is used for depositing the lead oxide. Regarding stoichiometric PbTiO3 deposition with reversed deposition order, the ratio of the first pulsing cycles (TiO2 growth) to the second pulsing cycles (PbO growth) is now preferably in the order of 1:10 - 1:30, again depending on the deposition temperature and choice of precursors.
Chemical examples:
Example 2
Materials and methods
Firm depositions were carried out in a commercial flow-type F- 120 atomic layer deposition reactor (ASM Microchemistry Ltd.). The pressure was 2-3 mbar in the reactor during the studies on the thin film deposition at temperatures of 250 and 300 0C. Tetraphenyllead (Ph4Pb, Aldrich Chem. Co., 97 %) and titanium isopropoxide (Ti(O1Pr)4, Aldrich Chem. Co., 97 %) were used as metal precursors. The metal precursors were evaporated inside the reactor from open source boats kept at 165 and 40°C, respectively. The reactants were alternately introduced into the reactor by using nitrogen as carrier and purging gas. Nitrogen (>99.999 %) was obtained from a nitrogen generator (Nitrox UHPN 3000-1). Ozone generated from oxygen (purity >99.999%) in an ozone generator (Fischer model 502) and water vaporized in a cylinder kept at 30 0C were used as oxygen sources for Ph4Pb and Ti(O1Pr)4, respectively. The size of the Si(IOO) (Okmetic, Finland) substrates used was 5x10 cm2.
At first, the deposition processes of binaiy oxides were studied in order to define the growth parameters for ternary oxide process. Uniform thin films were obtained when the reactant pulse durations used were 1.5 s and 0.6 s for Ph4Pb and Ti(O1Pr)4, respectively. Pulse duration for O3 was 2 s and for H2O 1 s. Purging times were between 1-2 s, depending on the pulsing times of the previous precursor.
When depositing ternary PbTiO3 thin films, the ratio of binary oxide layers was altered by changing the relative number of the Ph4PbZO3 and Ti(O1Pr)4TH2O pulses. The slash character denotes alternating sequential pulsing carried out according to the ALD method. The films were deposited by applying a plurality of lead oxide cycles followed by one titanium oxide cycle and then repeating that sequence. Typically, the number of lead oxide cycles was varied between 5 and 50. The total number of PbO/TiO2 layers was varied in order to control the total film thickness.
Thicknesses of the deposited PbTiO3 films were evaluated by Hitachi U- 2000 spectrometer using the wavelength region 190-1100 nm. Pb and Ti contents were measured using Philips PW 1480 X-ray fluorescence spectrometer equipped with a Rh X-ray tube.
The amount of any impurities was measured by Time-of-Flight Elastic Recoil Detection Analysis (TOF-ERDA) from selected samples. TOF-ERDA measurements were carried out at the Accelerator Laboratory of the University of Helsinki.
The film crystallinity and preferred orientations were studied by X-ray diffraction (Philips MPD 1880) using Cu Kα radiation. Selected samples were annealed in an RTA oven (PEO 601, ATV Technologie GmbH, Germany) in N2 or O2 (>99.999%) atmosphere at 500-900 0C for 10 minutes at atmospheric pressure. The heating rate of 20 °C/min and cooling rate of 25 °C/min were used. Surface morphologies of selected samples were studied with an atomic force microscope (AFM) AutoProbe CP (Park Scientific Instruments/Veeco) operated in the intermittent-contact mode using Ultralevels™ (Veeco) silicon-cantilevers. Roughness was calculated as root-mean-square (rms) values.
Results
The growth rate of PbO thin films was found to be 0.13 A/cycle at 250 °C and 0.10 A/cycle at 300 0C when using 1 - 1.5 s pulsing times for Ph4Pb. To obtain sufficient surface saturation, a pulse time of 1.5 s for Ph4Pb was used when depositing PbTiO3. Pulsing times were 2 s for ozone, 0.6 - 0.8 s for titanium isopropoxide and 1 s for water.
Because lead oxide had a lower growth rate than titanium dioxide, deposition Of PbTiO3 was started first with a variable number of lead oxide cycles (Ph4PbZO3), followed by one cycle of titanium dioxide (Ti(O1Pr)VHaO). Under constant deposition temperature and pulsing ratio the film thickness of PbTiO3 thin films was found to be linearly dependent on the number of depositing cycles.
XRF measurements showed that the Ti/Pb atomic ratio in films was dependent on the relative amount of the titanium pulses as seen in Fig. 6. The XRF results were calibrated by plotting the XRF Ti/Pb-ratio against the Ti/Pb-ratio measured by RBS. Results were in good congruency with each other. Stoichiometric films were obtained at 250 0C with a Ti:Pb pulsing ratio of 1:10 and at 3000C with a pulsing ratio of 1:28.
TOF-ERDA analyses performed showed that impurity levels were low and no other impurities than carbon and hydrogen were detected: carbon content was under 0.2 at-% and hydrogen content was 0.1 - 0.5 at-%. Example 3
Preparation of PbO2 films by Ph4Pb/O3 process
Lead oxide thin films were grown by ALD using tetraphenyl lead Ph4Pb as a lead precursor. The evaporation temperature was 165 to 170 0C. The effect of the deposition temperature on the growth rate was studied over a temperature range of 185 to 400 0C for the Ph4PWO3 process. Pulsing times for Ph4Pb were 1.0 to 3.0 s. The ozone pulse was varied in the range of 1.0 to 3.0 s and the nitrogen pulses between 1.0 and 2.5 s.
In case of Ph4Pb, the growth rate decreased with increasing deposition temperatures. A constant growth rate of 0.13 A/cycle was obtained at 200 to 250 °C. The effect of the Ph4Pb pulse times was examined at 250 0C and 300 0C. The growth rate was almost independent of the pulse time at 300 0C, and only a small increase in growth rate from 0.13 to 0.16 A/cycle was observed at 250 0C.
Firms deposited by Ph4PbZO3 process were polycrystalline, either orthorhombic (O) or tetragonal (T) lead dioxide (PbO2). The most intense reflection was T(IlO) if depositions were carried out below 300 °C. Above 300 0C, orientation changed so that the most intense reflection was 0(111).
According to TOF-ERDA, the lead-to-oxygen ratio was close to 0.7. Impurities levels were 0.5 at-% for carbon and less than 0.1 at-% for hydrogen at films deposited at 250 °C.
Graphical representations of the results
The attached drawings (Figures 3 to 7) depict graphically the results of ALD growth of lead oxide films:
FIG. 3 shows the growth rate of PbO2 thin firms as a function of the deposition temperature. Tetraphenyllead Ph4Pb was used as the lead precursor and ozone O3 was used as the oxygen precursor. The pulsing times for Ph4Pb and O3 were 1.0 s and 2.0 s, respectively. Constant growth rate Of PbO2 was obtained when the substrate temperature was in the range of 200 - 250 0C. For a comparison, an insert 300 shows the growth rate of PbO2 using Pb(thd)2 and O3 as precursors. The pulsing times for Pb(thd)2 and O3 were 1.0 s and 1.5 s, respectively. The substrate temperature affected rather strongly the growth rate Of PbO2.
FIG. 4 shows XRD patterns of PbO2 films deposited from Ph4Pb at 250 0C (a) and from Pb(thd)2 at 150 0C (b). The thickness for (a) was 70 nm and for (b) was 170 nm. Diffraction peeks were identified according to JCPDS cards 25-447 and 37-517.
FIG. 5 shows the growth rate of lead oxide thin films deposited at 250 0C and 300 0C using Ph4Pb as the Pb precursor with different Ph4Pb vapour pulse lengths. Pulsing time for O3 was 2.0 s and purging time 1.0-2.0 s depending on the precursor pulsing time.
FIG. 6 shows the ratio of titanium and lead content in Pb-Ti-O films deposited at 250 0C and 300 0C on Si(IOO) as a function of the precursor pulsing ratio. The film composition was measured by X-ray Fluorescence (XRF) and independently verified by Time-of-Flight Elastic Recoil Detection Analysis (TOF ERDA). Stoichiometric Pb-Ti oxide film is obtained when the Ti/Pb weight ratio is 0.23, shown with a horizontal dashed line 602.
FIG. 7 shows X-ray Diffraction (XRD) patterns Of PbTiO3 films annealed at 800 0C (a), 900 0C (b), and 1000 0C (c) in nitrogen N2 atmosphere for 10 min.
Example 4
Deposition Of PbMgNbO3, PbMgNbO3-PbTiO3 and PbMgNbO3-PbTiO3-BaTiO3 films
Lead magnesium niobate thin containing thin films can be deposited by using lead precursors of the present invention, such as Ph4Pb or Et4Pb, magnesium precursor, such as magnesium cyclopentadienyl Mg(Cp)2 or Mg(IM)2, niobium precursor, such as niobium ethoxide Nb(OEt)5 or other alkoxides, niobium chloride NbCl5 or fluoride NbF5 and oxygen precursor, such as water or ozone.
Mixing of lead titanate and/or barium titanate to the lead magnesium niobate can be performed by adjusting the cycle number of each sub-process. As an example, first one cycle of lead magnesium niobate is deposited and then one cycle of lead titanate is deposited. Further, one cycle of barium titanate can be deposited if desired. Deposition of lead magnesium containing thin films can be performed several ways. As an example one generalized way is presented for deposition niobium containing lead oxide films:
Sub-cvcle 1 (PMN):
Lead precursor, such as Ph4Pb or Et4Pb, is introduced to the substrate on a reaction space. After the lead precursor is introduced to the reaction space it will be purged with or without purge gas. After purge step, oxygen containing precursor, such as water or ozone, is introduced to the substrate on reaction space. After introducing the oxygen containing precursor the reaction space will be purged with or without purge gas. After purge step, niobium containing precursor, such as niobium ethoxide, is introduced to the substrate on reaction space. After the niobium precursor is introduced to the reaction space it will be purged with or without purge gas. After purge step, oxygen containing precursor, such as water or ozone, is introduced to the substrate on reaction space. After introducing the oxygen containing precursor the reaction space will be purged with or without purge gas. After purge step, magnesium containing precursor, such as bis(cyclopentadienyl)magnesium or bis(2,2,6,6-tetramethyl-3,5- heptanedionato)magnesium, is introduced to the substrate on reaction space. After the magnesium precursor is introduced to the reaction space it will be purged with or without purge gas. After purge step, one molecular layer of PbMgNbO3 is deposited on the substrate. This sub-cycle is repeated, if desired, as many times as necessary to form a film with desired composition and/or structure. Inside this sub-cycle the amount of metals to be deposited in the film can be adjusted just by skipping desired amount of one or more of the metal containing precursor pulses and the following oxygen containing precursor pulse.
Sub-cvcle 2 (PT):
Lead precursor, such as Ph4Pb or Et4Pb, is introduced to the substrate on a reaction space. After the lead precursor is introduced to the reaction space the reaction space will be purged with or without purge gas. After purge step, oxygen containing precursor, such as water or ozone, is introduced to the substrate on the reaction space. After introducing the oxygen containing precursor the reaction space will be purged with or without purge gas. After purge step, titanium containing precursor, such as titanium methoxide or titanium isopropoxide, is introduced to the substrate on reaction space. After the titanium precursor is introduced to the reaction space it will be purged with or without purge gas. After purge step, oxygen containing precursor, such as water or ozone, is introduced to the substrate on reaction space. After introducing the oxygen containing precursor the reaction space will be purged with or without purge gas. After purge step, one molecular layer of PbTiO3 is deposited on the substrate. This sub-cycle is repeated, if desired, as many times as necessary to form a film with desired composition and/or structure. Inside this sub-cycle the amount of metals to be deposited in the film can be adjusted just by skipping desired amount of one of the metal containing precursor pulses and the following oxygen containing precursor pulse.
Sub-cvcle 3 (BT):
Barium precursor, such as THF adduct bisφentametftylcyclopentadienyl)barium
Ba(C5(CH3)5)THFx, where x is 0-2, is introduced to the substrate on a reaction space. After the barium precursor is introduced to the reaction space the reaction space will be purged with or without purge gas. After purge step, oxygen containing precursor, such as water or ozone, is introduced to the substrate on the reaction space. After introducing the oxygen containing precursor the reaction space will be purged with or without purge gas. After purge step, titanium containing precursor, such as titanium methoxide or titanium isopropoxide, is introduced to the substrate on reaction space. After the titanium precursor is introduced to the reaction space it will be purged with or without purge gas. After purge step, oxygen containing precursor, such as water or ozone, is introduced to the substrate on reaction space. After introducing the oxygen containing precursor the reaction space will be purged with or without purge gas. After purge step, one molecular layer of BaTiO3 is deposited on the substrate. This sub-cycle is repeated, if desired, as many times as necessary to form a film with desired composition and/or structure. Inside this sub-cycle the amount of metals to be deposited in the film can be adjusted just by skipping desired amount of one of the metal containing precursor pulses and the following oxygen containing precursor pulse.
These three sub-cycles can be repeated, if desired, as many times as necessary to form a film with desired composition and/or structure. The amount of sub-cycles can be adjusted to match the desired composition/structure of the film by skipping skipping desired amount of sub-cycles. The order of the sub-cycles can also be changed.
Annealing at high temperature and desired atmospehere can be performed for crystallization after the deposition of lead magnesium niobate thin containing thin films.
Comparative Example
Preparation Of PbO2 films by a Pb(thd)2/O3 process
For comparative purposes, lead oxide films were deposited at ALD conditions using as a precursor for lead an organometallic compound, in which the ligand is attached to the metal atom via oxygen-metal bonds.
The evaporation temperature for bis(2,2,6,6-tetramethyl-3,5-heptanedionato)lead Pb(thd)2 was 110 - 115 0C. The effect of the deposition temperature on the growth rate was studied over a temperature range of 150 to 300 °C. Precursor pulsing and purging times were also studied in order to optimise the deposition process. Pulsing times studied for Pb(thd)2 were 1.0 - 3.0 s. Ozone pulse was varied between 1.0 and 3.0 s and the purging nitrogen pulse was varied in the range of 1.0 to 2.5 s.
In the case of Pb(thd)2 the growth rate increased with increasing deposition temperature. Also a clear thickness profile and dim and black film surface were observed at 250 0C and above. The growth rates for the Pb(thd)2 process were 1.0 to 1.5 A/cycle at temperatures below 200 °C and it increased up to 7.6 A/cycle, when the deposition temperature reached 300 0C .
Pulsing times for Pb(thd)2 were examined at 150 0C. At 1.0 s pulsing times, the films were smooth, and no differences were observed with longer pulsing times, indicating ALD type growth. The Pb(thd)2 pulse was then kept constant at 1.0 s and the ozone pulse was fixed between 1.0 and 3.0 s.
The thin films deposited from Pb(thd)2 were all crystalline regardless of the deposition temperatures. Below 200 0C the films were polycrystalline with orthorhombic (O) and tetragonal (T) lead dioxide (PbO2) phases. The most intense reflection at 150 0C was tetragonal (110), whereas at 200 0C, the most intense reflection was orthorhombic (111).
According to TOF-ERDA, the lead-to-oxygen ratio was close to 0.7. The impurity levels were 1.1 at-% for carbon and 0.1 at-% for hydrogen for films deposited at 150 0C.
While the invention has been described herein with reference to specific embodiments and features, one skilled in the art will recognize that various changes to the deposition conditions (e.g. substrate temperature and deposition pressure), precursor selections and thin film properties (e.g. composition, crystallinity and thickness) can be made without departing from the scope of the invention. Therefore, the scope of the invention should not be based upon the foregoing description. Rather, the scope of the invention should be determined based upon the claims recited herein, including the full scope of equivalents thereof.

Claims

Claims:
1. A process for producing lead containing oxide thin films by Atomic Layer Deposition, comprising using a metal-organic lead compound, having organic ligands bonded to a lead atom by carbon-lead bonds, as a source material for the lead oxide.
2. The process according to claim 1, comprising using a metal-organic lead compound with 2 or 4 alkyl ligands or ligands comprising aromatic groups.
3. The process according to claim 1 or 2, wherein the metal-organic lead compound has the formula
L1L2L3L4Pb
wherein each L1, L2, L3 and L4 is independently selected from
- linear or branched C1-C20 a^yl or alkenyl groups, preferably methyl, ethyl, n- and i- propyl, n-, sec- and t-butyl,
- halogenated alkyl or alkenyl groups, wherein at least one hydrogen atom is replaced with fluorine, chlorine, bromine or iodine atom, - carbocyclic groups, such as aryl, preferably phenyl, tolyl, xylyl, benzyl, alkylaryl groups, halogenated carbocyclic groups, and
- heterocyclic groups.
4. The process according to any of the preceding claims, comprising alternately feeding into a reaction space vapor phase pulses of
- a metal-organic lead compound and
- at least one oxygen source material capable of forming an oxide with the source material.
5. The process according to claim 4, comprising producing a multicomponent oxide thin film
6. The process according to claim 5 wherein the rmilticomponent oxide thin film comprises a second metal oxide selected from the group of bismuth, calcium, strontium, copper, titanium, tantalum, zirconium, hafnium, vanadium, niobium, chromium, tungsten, molybdenum, aluminum, rare earths and silicon oxides.
7. The process according to claim 5 or 6, wherein the multicomponent oxide thin film comprises PbTiO3 or PbNbO3.
8. The process according to claim 5 or 6, comprising producing a ternary oxide thin film.
9. The process according to any of claims 5 to 8, wherein the multicomponent oxide thin film comprises at least one further metal oxide selected from the group of lanthanum and zirconium oxides.
10. The process according to claim 9, wherein the multicomponent oxide thin film comprises Pb(Zr5Ti)O3 or (Pb,La)(Zr,Ti)O3.
11. The process according to any of claims 5 to 10, wherein the multicomponent oxide thin film comprises at least one more metal oxide selected from the group of magnesium and zinc oxides.
12. The process according to claim 11, wherein the multicomponent oxide thin film comprises Pb(Mg, Nb)O3 or Pb(Zn, Nb)O3.
13. The process according to claim 11, wherein the multicomponent oxide thin film comprises Pb(Mg, Nb)O3 and PbTiO3.
14. The process according to claim 11, wherein the multicomponent oxide thin film comprises Pb(Mg, Nb)O3, PbTiO3 and BaTiO3.
15. The process according to any of the preceding claims, wherein the source material of the lead oxide comprises tetraethyl lead or tetraphenyl lead.
16. The process according to any of the preceding claims, wherein the deposition temperature is about 150 to 400 °C.
17. The process according to any of claims 5 to 16, wherein the second metal oxide is deposited from a source material selected from the group of halides or metal organic compounds.
18. The process according to claim 17, wherein the source material is selected from the group of alkoxy, alkylamino, cyclopentadienyl, dithiocarbamate and betadiketonate compounds.
19. The process according to any of the preceding claims, wherein the oxygen source material is selected from the group of water, oxygen, hydrogen peroxide, aqueous solution of hydrogen peroxide, ozone, oxides of nitrogen, halide-oxygen compounds, peracids (-C(=O)-OOH), alcohols, alkoxides, oxygen-containing radicals and mixtures thereof.
20. The process according to claim 7, wherein the PbTiO3 film is annealed at a temperature over 500 0C in order to obtain a crystalline PbTiO3 film.
21. The process according to claim 20, wherein the PbTiO3 film is annealed at a temperature over 800 °C.
22. The process according to claim 20 or 21, wherein the PbTiO3 film is annealed in an inert atmosphere or in the presence of oxygen.
23. A process for forming lead containing multicomponent oxide thin firms by Atomic Layer Deposition on a substrate in a reaction space, comprising
- alternately feeding into said reaction space vapour phase pulses of a first metal source material, a second metal source material, and at least one oxygen source material capable of forming an oxide with the first metal source material and the second metal source material, wherein - said first metal source material is a metal-organic lead compound having optionally substituted alkyl or aryl ligands bonded by carbon-lead bonds to the lead atom of the lead compound, and
— said second metal source material is a volatile compound of at least one transition metal or main group metal of groups 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, and/or
14 (according to the system recommended by IUPAC) in the periodic table of elements.
24. The process according to claim 23, wherein the first metal source material is tetraethyl lead or tetraphenyl lead.
25. The process according to claim 23 or 24, wherein the oxygen source material is ozone or water.
26. The process according to any of claims 23 to 25, comprising producing a multicomponent film by feeding alternating pulses of the various metal precursors, followed by pulses of an oxygen source, into the reaction space.
27. The process according to claim 26, wherein the ratio of cycles consisting of lead containing precursor followed by oxygen source pulses to cycles consisting of a second metal source followed by the corresponding oxygen source pulses is about 50:1...1:50.
PCT/FI2005/000461 2004-10-26 2005-10-26 Method of depositing lead containing oxides films WO2006045885A1 (en)

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