WO2009155520A1 - Hafnium and zirconium pyrrolyl-based organometallic precursors and use thereof for preparing dielectric thin films - Google Patents

Hafnium and zirconium pyrrolyl-based organometallic precursors and use thereof for preparing dielectric thin films Download PDF

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WO2009155520A1
WO2009155520A1 PCT/US2009/047957 US2009047957W WO2009155520A1 WO 2009155520 A1 WO2009155520 A1 WO 2009155520A1 US 2009047957 W US2009047957 W US 2009047957W WO 2009155520 A1 WO2009155520 A1 WO 2009155520A1
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alkyl
butyl
precursor
group
formula
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Peter Nicholas Heys
Rajesh Odedra
Andrew Kingsley
Hywel Owen Davies
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Sigma-Aldrich Co.
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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
    • C23C16/06Chemical 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 metallic material
    • C23C16/18Chemical 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 metallic material from metallo-organic compounds
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07FACYCLIC, CARBOCYCLIC OR HETEROCYCLIC COMPOUNDS CONTAINING ELEMENTS OTHER THAN CARBON, HYDROGEN, HALOGEN, OXYGEN, NITROGEN, SULFUR, SELENIUM OR TELLURIUM
    • C07F7/00Compounds containing elements of Groups 4 or 14 of the Periodic Table
    • C07F7/003Compounds containing elements of Groups 4 or 14 of the Periodic Table without C-Metal linkages
    • 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]

Definitions

  • the present invention relates to pyrrolyl-based organometallic precursors and methods of preparing dielectric thin films by chemical vapor deposition (CVD) and atomic layer deposition (ALD) using such precursors.
  • CVD chemical vapor deposition
  • ALD atomic layer deposition
  • Various organometallic precursors are used to form high- ⁇ dielectric thin metal films.
  • a variety of techniques have been used for the deposition of thin films. These include reactive sputtering, ion-assisted deposition, sol-gel deposition, CVD, and ALD, also known at atomic layer epitaxy.
  • the CVD and ALD processes are being increasingly used as they have the advantages of good composition control, high film uniformity, good control of doping and, significantly, they give excellent conformal step coverage on highly non-planar microelectronics device geometries.
  • CVD also referred to as metalorganic CVD or MOCVD
  • MOCVD is a chemical process whereby precursors are deposited on a substrate to form a solid thin film.
  • ALD is another method for the deposition of thin films. It is a self -limiting, sequential, unique film growth technique based on surface reactions that can provide atomic layer-forming control and deposit-conformal thin films of materials provided by precursors onto substrates of varying compositions.
  • ALD the precursors are separated during the reaction.
  • the first precursor is passed over the substrate producing a monolayer on the substrate. Any excess unreacted precursor is pumped out of the reaction chamber.
  • a second precursor is then passed over the substrate and reacts with the first precursor, forming a second monolayer of film over the first-formed film on the substrate surface. This cycle is repeated to create a film of desired thickness.
  • ALD film growth is self-limited and based on surface reactions, creating uniform depositions that can be controlled at the nanometer- thickness scale.
  • Dielectric thin films have a variety of important applications, such as nanotechnology and fabrication of semiconductor devices. Examples of such applications include high-refractive index optical coatings, corrosion-protection coatings, photocatalytic self-cleaning glass coatings, biocompatible coatings, dielectric capacitor layers and gate dielectric insulating films in FETS, capacitor electrodes, gate electrodes, adhesive diffusion barriers and integrated circuits. Dielectric thin films are also used in microelectronics applications, such as the high-*; dielectric oxide for dynamic random access memory (DRAM) applications and the ferroelectric perovskites used in infra-red detectors and non-volatile ferroelectric random access memories (NV-FeRAMs). The continual decrease in the size of microelectronics components has increased the need for the use of such dielectric thin films.
  • DRAM dynamic random access memory
  • NV-FeRAMs non-volatile ferroelectric random access memories
  • Tanski J. and Parkin G. report a series of structurally characterized zirconium- pyrrolyl complexes. Organometallics , 21:587-589, (2002).
  • Dias et al. report the synthesis and characterization of the complex [Ti(NC 4 Me 4 )(NMe 2 )S] Collect. Czech. Chem. Commun. 63:182-186, (1998). [0010] Dias et al. report synthesis and characterization of titanium complexes containing 2,3,4,5-tetramethylpyrrolyl. J. Chem. Soc, Dalton Trans. 1055-1061, (1997). [0011] Bradley D. and Chivers K. report metallo-organic compounds such as Ti(NC 4 H 2 Me 2 )(NEt 2 )S. Inorg. Phys. Theor. 1967-1969, (1968).
  • a hafnium or zirconium organometallic precursor is provided.
  • the precursor corresponds in structure to Formula I:
  • R is independently selected from the group consisting of alkyl, alkoxy and NR 1 R 2 ; R 1 and R 2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4; Py is pyrrolyl; M is Hf or Zr; and
  • L is selected from the group consisting of alkyl, alkoxy and NR 1 R 2 .
  • Fig. 1 is a graphical representation of thermogravimetric analysis (TGA) data demonstrating % weight loss vs. temperature of ((te/t-butyl) 2 Py)Zr(NMe 2 ) 3 .
  • pyrrolyl-based organometallic precursors and methods of using such precursors to form thin metal-containing films are provided.
  • the methods of the invention are used to create or grow metal-containing thin films which display high dielectric constants.
  • a dielectric thin film as used herein refers to a thin film having a high permittivity.
  • high- ⁇ dielectric refers to a material, such as a metal-containing film, with a higher dielectric constant (K) when compared to silicon dioxide (which has a dielectric constant of about 3.7).
  • K dielectric constant
  • a high- ⁇ dielectric film is used in semiconductor manufacturing processes to replace a silicon dioxide gate dielectric.
  • a high- ⁇ dielectric film may be referred to as having a "high- ⁇ gate property" when the dielectric film is used as a gate material and has at least a higher dielectric constant than silicon dioxide.
  • vapor deposition process is used to refer to any type of vapor deposition technique such as CVD or ALD.
  • CVD may take the form of conventional CVD, liquid injection CVD or photo- assisted CVD.
  • ALD may take the form of conventional ALD, liquid injection ALD or photo-assisted ALD.
  • precursor refers to an organometallic molecule, complex and/or compound which is deposited or delivered to a substrate to form a thin film by a vapor deposition process such as CVD or ALD.
  • the precursor may be dissolved in an appropriate hydrocarbon or amine solvent.
  • hydrocarbon solvents include, but are not limited, to aliphatic hydrocarbons, such as hexane, heptane and nonane; aromatic hydrocarbons, such as toluene and xylene; aliphatic and cyclic ethers, such as diglyme, triglyme and tetraglyme.
  • appropriate amine solvents include, without limitation, octylamine and N,N-dimethyldodecylamine.
  • the precursor may be dissolved in toluene to yield a 0.05 to IM solution.
  • the term “Py” refers to a pyrrolyl ligand which is bound to a metal center.
  • alkyl (alone or in combination with another term(s)) refers to a saturated hydrocarbon chain of 1 to about 10 carbon atoms in length, such as, but not limited to, methyl, ethyl, propyl and butyl.
  • the alkyl group may be straight-chain or branched-chain.
  • propyl encompasses both w-propyl and iso- propyl; butyl encompasses w-butyl, sec-butyl, iso-butyl and tert-butyl.
  • Me refers to methyl
  • Et refers to ethyl
  • iPr refers to iso-propyl
  • tBu refers to tert-butyl.
  • alkoxy refers to a substituent, i.e., -O-alkyl.
  • substituents include methoxy (-0-CH 3 ), ethoxy, etc.
  • the alkyl portion may be straight-chain or branched-chain.
  • propoxy encompasses both w-propoxy and iso-propoxy; butoxy encompasses w-butoxy, zso-butoxy, sec-butoxy, and tert-butoxy.
  • amino herein refers to an optionally substituted monovalent nitrogen atom (i.e., -NR 1 R 2 , where R 1 and R 2 can be the same or different).
  • amino groups encompassed by the invention include, but are not limited to, -I -N(Me) 2
  • R 1 and R 2 are independently hydrogen or alkyl.
  • an organometallic precursor is provided.
  • the organometallic precursor corresponds in structure to Formula I:
  • R is independently selected from the group consisting of alkyl, alkoxy and NR 1 R 2 ;
  • R 1 and R 2 are each independently hydrogen or alkyl;
  • n is zero, 1, 2, 3 or 4;
  • Py is pyrrolyl
  • M is Hf or Zr
  • L is selected from the group consisting of alkyl, alkoxy and NR 1 R 2
  • the metal center of the precursor according to Formula I is comprised of a
  • Group IVB metal i.e. hafnium or zirconium.
  • R is alkyl, such as methyl, ethyl, propyl, or butyl.
  • R is alkoxy, such as methoxy, ethoxy, propoxy or butoxy.
  • R is NR 1 R 2 , wherein R 1 and R 2 are each independently hydrogen or alkyl.
  • R is N(Me) 2 or
  • n is the number of R groups substituted on the pyrrolyl ligand.
  • n is 1, 2, 3, or 4. In another embodiment, n is 2, 3 or 4. In another embodiment, n is 2 or 3. In a further particular embodiment, n is 2.
  • Each L substituent is the same. This can be referred to as a "piano stool" arrangement.
  • L is alkyl, such as methyl, ethyl, propyl, or butyl.
  • L is alkoxy, such as methoxy, ethoxy, propoxy or butoxy.
  • L is NR 1 R 2 , wherein R 1 and R 2 are each independently hydrogen or alkyl.
  • R 1 and R 2 are each independently hydrogen or alkyl.
  • L is N(Me) 2 or
  • the at least one precursor corresponds in structure to
  • R is independently alkyl or alkoxy
  • R 1 and R 2 are each independently hydrogen or alkyl; n is 1, 2, 3 or 4; Py is pyrrolyl;
  • M is Hf or Zr
  • L is alkoxy or NR 1 R 2
  • the at least one precursor corresponds in structure to
  • M is Zr
  • R is independently methyl, ethyl, propyl or butyl; n is zero, 1, 2, 3, or 4; and
  • L is methoxy, ethoxy, propoxy, butoxy, N(Me) 2 or N(Me)(Et).
  • the at least one precursor corresponds in structure to
  • M is Hf
  • R is independently methyl, ethyl, propyl or butyl; n is zero, 1, 2, 3, or 4; and
  • L is methoxy, ethoxy, propoxy, butoxy, N(Me) 2 or N(Me)(Et).
  • the at least one precursor corresponds in structure to
  • M is Zr
  • R is independently methyl, ethyl, propyl or butyl; n is 1, 2, 3, or 4; and
  • L is methoxy, ethoxy, propoxy, butoxy, N(Me) 2 or N(Me)(Et).
  • the at least one precursor corresponds in structure to
  • M is Hf
  • R is independently methyl, ethyl, propyl or butyl; n is 1, 2, 3, or 4; and
  • L is methoxy, ethoxy, propoxy, butoxy, N(Me) 2 or N(Me)(Et).
  • the at least one precursor corresponding in structure to Formula I is:
  • each X can be the same or different and corresponds in structure to [(R) n Py]M(L) 3 wherein:
  • R is independently selected from the group consisting of alkyl, alkoxy and NR 1 R 2 ;
  • R 1 and R 2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4;
  • Py is pyrrolyl
  • M is Hf or Zr
  • L is selected from the group consisting of alkyl, alkoxy and NR 1 R 2 [0045]
  • a method of forming a metal-containing film by a vapor deposition process is provided.
  • the vapor deposition process is chemical vapor deposition.
  • the vapor deposition process is atomic layer deposition.
  • the method comprises delivering at least one precursor to a substrate, wherein the at least one precursor corresponds in structure to Formula I and/or II above.
  • the ALD and CVD methods of the invention encompass various types of ALD and CVD processes such as, but not limited to, conventional processes, liquid injection processes and photo-assisted processes.
  • conventional CVD is used to form a metal-containing thin film using at least one precursor according to Formula I and/or II.
  • CVD processes see for example Smith, Donald (1995). Thin-Film Deposition: Principles and Practice. McGraw-Hill.
  • liquid injection CVD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II.
  • liquid injection CVD growth conditions include, but are not limited to:
  • photo-assisted CVD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II.
  • conventional ALD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II.
  • ALD pulsed injection ALD process
  • liquid injection ALD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II, wherein at least one liquid precursor is delivered to the reaction chamber by direct liquid injection as opposed to vapor draw by a bubbler.
  • liquid injection ALD process see, for example, Potter R. J., et. al. Chem. Vap. Deposition. 2005. 11(3): 159.
  • Examples of liquid injection ALD growth conditions include, but are not limited to:
  • Pulse sequence (sec.) (precursor/purge/H 2 O/purge): will vary according to chamber size.
  • photo-assisted ALD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II.
  • the organometallic precursors according to Formula I and/or II utilized in these methods may be liquid, solid, or gaseous. Particularly, the precursors are liquid at ambient temperatures with high vapor pressure allowing for consistent transport of the vapor to the process chamber.
  • the precursors corresponding to Formula I and/or II are delivered to the substrate in pulses alternating with pulses of an oxygen source, such as a reactive oxygen species.
  • oxygen source such as a reactive oxygen species.
  • oxygen source include, without limitation, H 2 O, O 2 and/or ozone.
  • the method further comprises delivering for deposition at least one co-precursor to form a "mixed" metal film.
  • the method further comprises delivering for deposition at least one co-precursor to form a mixed metal oxide film.
  • a mixed metal oxide film contains at least two different metals.
  • two or more precursors corresponding in structure to Formula I and/or II may be used to form a mixed metal oxide film.
  • a hafnium and zirconium precursor can be used to create a hafnium-zirconium oxide film.
  • a hafnium or zirconium precursor corresponding in structure to Formula I and/or II may be used in CVD or ALD with at least one titanium, strontium, bismuth, barium or lanthanum precursor to form a mixed metal oxide film.
  • Examples of such mixed metal oxide films formed include, without limitation, SrZrO 3 , SrHfO 3 , LaZrO 3 and LaHfO 3 .
  • a dielectric film can also be formed by the at least one precursor corresponding to Formula I and/or II, independently or in combination with a co-reactant.
  • co-reactants include, but are not limited to, hydrogen, hydrogen plasma, oxygen, air, water, H 2 O 2 , ammonia, hydrazine, alkylhydrazine, borane, silane, ozone or any combination thereof.
  • substrates can be used in the methods of the present invention.
  • the precursors according to Formula I and/or II may be delivered for deposition on substrates such as, but not limited to, silicon, silicon oxide, silicon nitride, tantalum, tantalum nitride, copper, ruthenium, titanium nitride, tungsten, and tungsten nitride.
  • the method of the invention is utilized for applications such as dynamic random access memory (DRAM) and complementary metal oxide semi-conductor (CMOS) for memory and logic applications on silicon chips.
  • DRAM dynamic random access memory
  • CMOS complementary metal oxide semi-conductor
  • the requirements for precursor properties to achieve optimum performance vary greatly.
  • CVD a clean thermal decomposition of the precursor to deposit the required species onto the substrate is critical.
  • ALD such a thermal decomposition is to be avoided at all costs.
  • ALD the reaction between the input reagents must be rapid and result in the target material formation on the substrate.
  • any such reaction between species is detrimental due to their gas phase mixing before reaching the substrate to generate particles.
  • a good CVD source will be a poor ALD source and vice versa and therefore it is surprising that the pyrrolyl-based molecules of this invention perform well in both ALD and CVD processes.
  • the pyrrolyl-based precursors offer access to different temperature windows for deposition processes when compared to conventional precursors. This makes matching of these pyrrolyl-based precursors with other metal sources open to more manipulation when attempting to deposit ternary or quaternary alloys in an optimized fashion.
  • Auger electron spectroscopy is carried out on a Varian scanning Auger spectrometer.
  • the atomic compositions are quoted from the bulk of the film (typically 70 - 80 nm depth), free from surface contamination, and are obtained by combining AES with sequential argon ion bombardment until comparable compositions are obtained for consecutive data points.
  • Compositions are based on a HfO 2 or ZrO 2 powder reference.
  • Figure 1 represents TGA data for [(te/t-butyl) 2 pyrrolyl]Zr[N(CH 3 ) 2 ] 3 .
  • TGA Thermogravimetic Analysis
  • AIX 200FE AVD reactor fitted with a modified liquid injection system.
  • oxygen is introduced at the inlet of the reactor.
  • the oxygen is replaced by ozone, which is controlled by a pneumatic valve.
  • the substrate is rotated throughout the CVD experiments. Films of ZrO 2 or HfO 2 are deposited on Si
  • Pulse sequence (sec.) [Zr precursor]/purge/water/purge/— 2 / 2/ 0.5 / 3.5

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Abstract

Hafnium and zirconium pyrrolyl-based organometallic precursors and methods of use thereof are provided to prepare metal-containing dielectric thin films by a vapor deposition process. The organometallic precursors correspond in structure to Formula I or dimers of Formula I: [(R)nPy]M(L)3 (Formula I) wherein: R is independently selected from the group consisting of alkyl, alkoxy and NR1R2; R1 and R2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4; Py is pyrrolyl; M is Hf or Zr; L is selected from the group consisting of alkyl, alkoxy and NR1R2.

Description

HAFNIUM AND ZIRCONIUM PYRROLYL-BASED ORGANOMETALLIC PRECURSORS AND USE THEREOF FOR PREPARING DIELECTRIC THIN
FILMS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent claims the benefit of U.S. provisional application Serial No. 61/074,363, filed on 20 June 2008, U.S. provisional application Serial No. 61/177,137, filed on 11 May 2009 and U.S. provisional application Serial No. 61/177,165, filed on 11 May 2009. The disclosure of each recited U.S. provisional application is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to pyrrolyl-based organometallic precursors and methods of preparing dielectric thin films by chemical vapor deposition (CVD) and atomic layer deposition (ALD) using such precursors.
BACKGROUND OF THE INVENTION
[0003] Various organometallic precursors are used to form high-κ dielectric thin metal films. A variety of techniques have been used for the deposition of thin films. These include reactive sputtering, ion-assisted deposition, sol-gel deposition, CVD, and ALD, also known at atomic layer epitaxy. The CVD and ALD processes are being increasingly used as they have the advantages of good composition control, high film uniformity, good control of doping and, significantly, they give excellent conformal step coverage on highly non-planar microelectronics device geometries. [0004] CVD (also referred to as metalorganic CVD or MOCVD) is a chemical process whereby precursors are deposited on a substrate to form a solid thin film. In a typical CVD process, the precursors are passed over a substrate (wafer) within a low pressure or ambient pressure reaction chamber. The precursors react and/or decompose on the substrate surface creating a thin film of deposited material. Volatile by-products are removed by gas flow through the reaction chamber. The deposited film thickness can be difficult to control because it depends on coordination of many parameters such as temperature, pressure, gas flow volumes and uniformity, chemical depletion effects and time. [0005] ALD is another method for the deposition of thin films. It is a self -limiting, sequential, unique film growth technique based on surface reactions that can provide atomic layer-forming control and deposit-conformal thin films of materials provided by precursors onto substrates of varying compositions. In ALD, the precursors are separated during the reaction. The first precursor is passed over the substrate producing a monolayer on the substrate. Any excess unreacted precursor is pumped out of the reaction chamber. A second precursor is then passed over the substrate and reacts with the first precursor, forming a second monolayer of film over the first-formed film on the substrate surface. This cycle is repeated to create a film of desired thickness. ALD film growth is self-limited and based on surface reactions, creating uniform depositions that can be controlled at the nanometer- thickness scale.
[0006] Dielectric thin films have a variety of important applications, such as nanotechnology and fabrication of semiconductor devices. Examples of such applications include high-refractive index optical coatings, corrosion-protection coatings, photocatalytic self-cleaning glass coatings, biocompatible coatings, dielectric capacitor layers and gate dielectric insulating films in FETS, capacitor electrodes, gate electrodes, adhesive diffusion barriers and integrated circuits. Dielectric thin films are also used in microelectronics applications, such as the high-*; dielectric oxide for dynamic random access memory (DRAM) applications and the ferroelectric perovskites used in infra-red detectors and non-volatile ferroelectric random access memories (NV-FeRAMs). The continual decrease in the size of microelectronics components has increased the need for the use of such dielectric thin films.
[0007] Tanski J. and Parkin G. report a series of structurally characterized zirconium- pyrrolyl complexes. Organometallics , 21:587-589, (2002).
[0008] Choukroun et al. report reactivity of the titanium-nitrogen bond in the mixed trisalkoxy dialkylamide derivative Ti(OR)3(NEt2). Synth. React. Inorg. Met.-Org. Chem. 8(2):137-147, (1978).
[0009] Dias et al. report the synthesis and characterization of the complex [Ti(NC4Me4)(NMe2)S] Collect. Czech. Chem. Commun. 63:182-186, (1998). [0010] Dias et al. report synthesis and characterization of titanium complexes containing 2,3,4,5-tetramethylpyrrolyl. J. Chem. Soc, Dalton Trans. 1055-1061, (1997). [0011] Bradley D. and Chivers K. report metallo-organic compounds such as Ti(NC4H2Me2)(NEt2)S. Inorg. Phys. Theor. 1967-1969, (1968).
[0012] Current precursors for use in CVD and ALD do not provide the required performance to implement new processes for fabrication of next generation devices, such as semi-conductors. For example, improved thermal stability, higher volatility, increased deposition rates and a high permittivity are needed.
SUMMARY OF THE INVENTION
[0013] In one embodiment a hafnium or zirconium organometallic precursor is provided. The precursor corresponds in structure to Formula I:
[(R)nPy]M(L)3
(Formula I) wherein:
R is independently selected from the group consisting of alkyl, alkoxy and NR1R2; R1 and R2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4; Py is pyrrolyl; M is Hf or Zr; and
L is selected from the group consisting of alkyl, alkoxy and NR1R2. [0014] In another embodiment, a method of forming a metal-containing film by a vapor deposition process is provided. The method comprises delivering at least one precursor to a substrate, wherein the at least one precursor corresponds in structure to Formula I above.
[0015] Other embodiments, including particular aspects of the embodiments summarized above, will be evident from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Fig. 1 is a graphical representation of thermogravimetric analysis (TGA) data demonstrating % weight loss vs. temperature of ((te/t-butyl)2Py)Zr(NMe2)3.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In various aspects of the invention, pyrrolyl-based organometallic precursors and methods of using such precursors to form thin metal-containing films, such as metal oxide films or metal nitride films, are provided. [0018] The methods of the invention are used to create or grow metal-containing thin films which display high dielectric constants. A dielectric thin film as used herein refers to a thin film having a high permittivity.
A. Definitions
[0019] As used herein, the term "high-κ dielectric" refers to a material, such as a metal-containing film, with a higher dielectric constant (K) when compared to silicon dioxide (which has a dielectric constant of about 3.7). Typically, a high-κ dielectric film is used in semiconductor manufacturing processes to replace a silicon dioxide gate dielectric. A high-κ dielectric film may be referred to as having a "high-κ gate property" when the dielectric film is used as a gate material and has at least a higher dielectric constant than silicon dioxide.
[0020] As used herein, the term "relative permittivity" is synonymous with dielectric constant (K).
[0021] As used herein, the term "vapor deposition process" is used to refer to any type of vapor deposition technique such as CVD or ALD. In various embodiments of the invention, CVD may take the form of conventional CVD, liquid injection CVD or photo- assisted CVD. In other embodiments, ALD may take the form of conventional ALD, liquid injection ALD or photo-assisted ALD.
[0022] As used herein, the term "precursor" refers to an organometallic molecule, complex and/or compound which is deposited or delivered to a substrate to form a thin film by a vapor deposition process such as CVD or ALD.
[0023] In a particular embodiment, the precursor may be dissolved in an appropriate hydrocarbon or amine solvent. Appropriate hydrocarbon solvents include, but are not limited, to aliphatic hydrocarbons, such as hexane, heptane and nonane; aromatic hydrocarbons, such as toluene and xylene; aliphatic and cyclic ethers, such as diglyme, triglyme and tetraglyme. Examples of appropriate amine solvents include, without limitation, octylamine and N,N-dimethyldodecylamine. For example, the precursor may be dissolved in toluene to yield a 0.05 to IM solution.
[0024] As used herein, the term "Py" refers to a pyrrolyl ligand which is bound to a metal center. [0025] The term "alkyl" (alone or in combination with another term(s)) refers to a saturated hydrocarbon chain of 1 to about 10 carbon atoms in length, such as, but not limited to, methyl, ethyl, propyl and butyl. The alkyl group may be straight-chain or branched-chain. For example, as used herein, propyl encompasses both w-propyl and iso- propyl; butyl encompasses w-butyl, sec-butyl, iso-butyl and tert-butyl. Further, as used herein, "Me" refers to methyl, "Et" refers to ethyl, "iPr" refers to iso-propyl and "tBu" refers to tert-butyl.
[0026] The term "alkoxy" (alone or in combination with another term(s)) refers to a substituent, i.e., -O-alkyl. Examples of such a substituent include methoxy (-0-CH3), ethoxy, etc. The alkyl portion may be straight-chain or branched-chain. For example, as used herein, propoxy encompasses both w-propoxy and iso-propoxy; butoxy encompasses w-butoxy, zso-butoxy, sec-butoxy, and tert-butoxy.
[0027] The term "amino" herein refers to an optionally substituted monovalent nitrogen atom (i.e., -NR1R2, where R1 and R2 can be the same or different). Examples of
amino groups encompassed by the invention include, but are not limited to, -I -N(Me)2
4* -N(Et)2 — <-N(Et)(Me) and s and *> . Further, the nitrogen atom of this amino group is covalently bonded to the metal center which together may be referred to as an "amide"
group (i.e.
Figure imgf000007_0001
This can be further referred to as an "ammono" group or
- I|-Hf— N /R1 _ §|_Zr_N /' R1 inorganic amide, for example R2 or R2 wherein R1 and R2 are independently hydrogen or alkyl.
B. Organometallic Precursors
[0028] In a first embodiment, an organometallic precursor is provided. The organometallic precursor corresponds in structure to Formula I:
[(R)nPy]M(L)3
(Formula I) wherein: R is independently selected from the group consisting of alkyl, alkoxy and NR1R2; R1 and R2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4;
Py is pyrrolyl;
M is Hf or Zr;
L is selected from the group consisting of alkyl, alkoxy and NR1R2
[0029] The metal center of the precursor according to Formula I is comprised of a
Group IVB metal, i.e. hafnium or zirconium.
[0030] In one embodiment, R is alkyl, such as methyl, ethyl, propyl, or butyl.
[0031] In another embodiment, R is alkoxy, such as methoxy, ethoxy, propoxy or butoxy.
[0032] In yet another embodiment, R is NR1R2, wherein R1 and R2 are each independently hydrogen or alkyl. For example, in one embodiment, R is N(Me)2 or
NH(Me) or N(Et)2 or NH(Et) or N(Me)(Et).
[0033] The variable n is the number of R groups substituted on the pyrrolyl ligand.
There may be from zero to four R groups substituted on the pyrrolyl ligand. If more than one R group is present, the R groups may be the same or different. In a particular embodiment, n is 1, 2, 3, or 4. In another embodiment, n is 2, 3 or 4. In another embodiment, n is 2 or 3. In a further particular embodiment, n is 2.
[0034] There are three L substituents bonded to the metal center. Each L substituent is the same. This can be referred to as a "piano stool" arrangement.
[0035] In one embodiment, L is alkyl, such as methyl, ethyl, propyl, or butyl.
[0036] In another embodiment, L is alkoxy, such as methoxy, ethoxy, propoxy or butoxy.
[0037] In yet another embodiment, L is NR1R2, wherein R1 and R2 are each independently hydrogen or alkyl. For example, in one embodiment, L is N(Me)2 or
NH(Me) or N(Et)2 or NH(Et) or N(Me)(Et).
[0038] In one embodiment, the at least one precursor corresponds in structure to
Formula I wherein:
R is independently alkyl or alkoxy;
R1 and R2 are each independently hydrogen or alkyl; n is 1, 2, 3 or 4; Py is pyrrolyl;
M is Hf or Zr; and
L is alkoxy or NR1R2
[0039] In another embodiment, the at least one precursor corresponds in structure to
Formula I wherein:
M is Zr;
R is independently methyl, ethyl, propyl or butyl; n is zero, 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
[0040] In another embodiment, the at least one precursor corresponds in structure to
Formula I wherein:
M is Hf;
R is independently methyl, ethyl, propyl or butyl; n is zero, 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
[0041] In another embodiment, the at least one precursor corresponds in structure to
Formula I wherein:
M is Zr;
R is independently methyl, ethyl, propyl or butyl; n is 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
[0042] In another embodiment, the at least one precursor corresponds in structure to
Formula I wherein:
M is Hf;
R is independently methyl, ethyl, propyl or butyl; n is 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
[0043] In a particular embodiment, the at least one precursor corresponding in structure to Formula I is:
(Py)Zr(NMe2)3;
(Me2Py)Zr(NMe2)3; [(te/t-butyl)2Py]Zr(NMe2)3 ; (Py)Hf(NMe2)3 ; (Me2Py)Hf(NMe2)3 ; [(te/t-butyl)2Py]Hf(NMe2)3; (Py)Zr(O1Pr)3; (Me2Py)Zr(O1Pr)3; [(fert-butyl)2Py]Zr(O1Pr)3; (Py)Hf(O1Pr)3; (Me2Py)Hf(O1Pr)3; and [(tert-butylhPyWiO'Prh.
[0044] The precursors described above can all be referred to as monomers. However, it is possible that the monomers may also dimerize. Thus, in another embodiment dimers of the above disclosed monomers are also provided. These organometallic precursors correspond in structure to Formula II:
X:X
(Formula II) wherein: each X can be the same or different and corresponds in structure to [(R)nPy]M(L)3 wherein:
R is independently selected from the group consisting of alkyl, alkoxy and NR1R2;
R1 and R2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4;
Py is pyrrolyl;
M is Hf or Zr; and
L is selected from the group consisting of alkyl, alkoxy and NR1R2 [0045] Each of the embodiments recited above for Formula I precursors may be applied mutatis mutandis to the organometallic precursors of Formula II.
C. Methods of Use
[0046] In another embodiment a method of forming a metal-containing film by a vapor deposition process is provided. [0047] In one embodiment, the vapor deposition process is chemical vapor deposition.
[0048] In another embodiment, the vapor deposition process is atomic layer deposition.
[0049] The method comprises delivering at least one precursor to a substrate, wherein the at least one precursor corresponds in structure to Formula I and/or II above. [0050] The ALD and CVD methods of the invention encompass various types of ALD and CVD processes such as, but not limited to, conventional processes, liquid injection processes and photo-assisted processes.
[0051] In one embodiment, conventional CVD is used to form a metal-containing thin film using at least one precursor according to Formula I and/or II. For conventional CVD processes, see for example Smith, Donald (1995). Thin-Film Deposition: Principles and Practice. McGraw-Hill.
[0052] In another embodiment, liquid injection CVD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II. [0053] Examples of liquid injection CVD growth conditions include, but are not limited to:
(1) Substrate temperature: 200-6000C on Si(IOO)
(2) Evaporator temperature: about 2000C
(3) Reactor pressure: about 5mbar
(4) Solvent: toluene, or any solvent mentioned above
(5) Solution concentration: about 0.05 M
(6) Injection rate: about 30 cmV
(7) Argon flow rate: about 200 cm3 min 1
(8) Oxygen flow rate: about 100 cm3 min"1
(9) Run time: 10 min
[0054] In another embodiment, photo-assisted CVD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II. [0055] In a further embodiment, conventional ALD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II. For conventional and/or pulsed injection ALD process see, for example, George S. M., et. al. J. Phys. Chem. 1996. 100:13121-13131.
[0056] In another embodiment, liquid injection ALD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II, wherein at least one liquid precursor is delivered to the reaction chamber by direct liquid injection as opposed to vapor draw by a bubbler. For liquid injection ALD process see, for example, Potter R. J., et. al. Chem. Vap. Deposition. 2005. 11(3): 159. [0057] Examples of liquid injection ALD growth conditions include, but are not limited to:
(1) Substrate temperature: 160-3000C on Si(IOO)
(2) Evaporator temperature: about 1750C
(3) Reactor pressure: about 5mbar
(4) Solvent: toluene, or any solvent mentioned above
(5) Solution concentration: about 0.05 M
(6) Injection rate: about 2.5μl pulse"1 (4 pulses cycle"1)
(7) Inert gas flow rate: about 200 cm3 min"1
(8) Pulse sequence (sec.) (precursor/purge/H2O/purge): will vary according to chamber size.
(9) Number of cycles: will vary according to desired film thickness.
[0058] In another embodiment, photo-assisted ALD is used to form a metal- containing thin film using at least one precursor according to Formula I and/or II. For photo-assisted ALD processes see, for example, U.S. Patent No. 4,581,249. [0059] Thus, the organometallic precursors according to Formula I and/or II utilized in these methods may be liquid, solid, or gaseous. Particularly, the precursors are liquid at ambient temperatures with high vapor pressure allowing for consistent transport of the vapor to the process chamber.
[0060] In one embodiment, the precursors corresponding to Formula I and/or II are delivered to the substrate in pulses alternating with pulses of an oxygen source, such as a reactive oxygen species. Examples of such oxygen source include, without limitation, H2O, O2 and/or ozone.
D. Mixed Metal Films [0061] In another embodiment of the invention, the method further comprises delivering for deposition at least one co-precursor to form a "mixed" metal film. [0062] In a particular embodiment, the method further comprises delivering for deposition at least one co-precursor to form a mixed metal oxide film. As used herein, a mixed metal oxide film contains at least two different metals.
[0063] In one embodiment, two or more precursors corresponding in structure to Formula I and/or II may be used to form a mixed metal oxide film. For example, a hafnium and zirconium precursor can be used to create a hafnium-zirconium oxide film. [0064] In another embodiment, a hafnium or zirconium precursor corresponding in structure to Formula I and/or II may be used in CVD or ALD with at least one titanium, strontium, bismuth, barium or lanthanum precursor to form a mixed metal oxide film. Examples of such mixed metal oxide films formed include, without limitation, SrZrO3, SrHfO3, LaZrO3 and LaHfO3.
E. Co-Reactants
[0065] A dielectric film can also be formed by the at least one precursor corresponding to Formula I and/or II, independently or in combination with a co-reactant. Examples of such co-reactants include, but are not limited to, hydrogen, hydrogen plasma, oxygen, air, water, H2O2, ammonia, hydrazine, alkylhydrazine, borane, silane, ozone or any combination thereof.
F. Substrates
[0066] A variety of substrates can be used in the methods of the present invention. For example, the precursors according to Formula I and/or II may be delivered for deposition on substrates such as, but not limited to, silicon, silicon oxide, silicon nitride, tantalum, tantalum nitride, copper, ruthenium, titanium nitride, tungsten, and tungsten nitride.
G. Applications
[0067] In particular embodiments, the method of the invention is utilized for applications such as dynamic random access memory (DRAM) and complementary metal oxide semi-conductor (CMOS) for memory and logic applications on silicon chips. [0068] Fundamental differences exist between the thermally-driven CVD process and the reactivity-driven ALD process. The requirements for precursor properties to achieve optimum performance vary greatly. In CVD a clean thermal decomposition of the precursor to deposit the required species onto the substrate is critical. However, in ALD such a thermal decomposition is to be avoided at all costs. In ALD the reaction between the input reagents must be rapid and result in the target material formation on the substrate. However, in CVD any such reaction between species is detrimental due to their gas phase mixing before reaching the substrate to generate particles. In general, a good CVD source will be a poor ALD source and vice versa and therefore it is surprising that the pyrrolyl-based molecules of this invention perform well in both ALD and CVD processes.
[0069] The pyrrolyl-based precursors offer access to different temperature windows for deposition processes when compared to conventional precursors. This makes matching of these pyrrolyl-based precursors with other metal sources open to more manipulation when attempting to deposit ternary or quaternary alloys in an optimized fashion.
EXAMPLES
[0070] The following examples are merely illustrative, and do not limit this disclosure in any way.
[0071] All manipulations are carried out under an atmosphere of dry nitrogen using standard Schlenk line or dry box techniques. Dry solvents and other starting materials are supplied by Sigma- Aldrich Ltd. and are purified where necessary.
[0072] Auger electron spectroscopy (AES) is carried out on a Varian scanning Auger spectrometer. The atomic compositions are quoted from the bulk of the film (typically 70 - 80 nm depth), free from surface contamination, and are obtained by combining AES with sequential argon ion bombardment until comparable compositions are obtained for consecutive data points. Compositions are based on a HfO2 or ZrO2 powder reference.
[0073] Example 1 - Preparation of [tort-butyl)?pyrrolyllZr[N(CHO?^
Figure imgf000014_0001
[0074] To a solution of Zr(N(CH3)2)4 (1.5g, 0.0056 moles) in toluene (20ml) was added via canula a solution of (te/t-butyl)2(pyrrole) (l.Og, 0.0056 moles) in toluene
(20 mis) at room temperature. The solution was heated to 7O0C for 3 hours and the solvent removed leaving [(fert-butyl)2pyrrolyl]Zr[N(CH3)2]3 as a low melting
(~30°C) white solid. 1H NMR spectroscopy was carried out on a Bruker Avance 400
NMR spectrometer (1H 400.1 MHz). NMR: 1.3 ppm (t-butyl), 3.1 ppm (NMe2)3, and
6.1 ppm (pyrrolyl).
[0075] Figure 1 represents TGA data for [(te/t-butyl)2pyrrolyl]Zr[N(CH3)2]3.
Thermogravimetic Analysis (TGA) was carried out on a Mettler Toledo thermogravimetric analyzer in a nitrogen filled glove box.
[0076] Example 2 - CVD and ALD studies
[0077] Liquid injection CVD and ALD experiments are carried out on an Aixtron
AIX 200FE AVD reactor fitted with a modified liquid injection system. During the CVD experiments, oxygen is introduced at the inlet of the reactor. For the ALD experiments, the oxygen is replaced by ozone, which is controlled by a pneumatic valve. The substrate is rotated throughout the CVD experiments. Films of ZrO2 or HfO2 are deposited on Si
(100) substrates using 0.05M solutions of precursor in toluene.
[0078] Exemplary CVD and ALD growth conditions which may be effective for deposition are shown in Table 1.
Table 1. Possible growth conditions for the deposition of ZrO2 films by liquid injection CVD and ALD using [tert-butyl)?pyrrolyllZr[N(CHO?^
Figure imgf000015_0001
Pulse sequence (sec.) [Zr precursor]/purge/water/purge/— 2 / 2/ 0.5 / 3.5
[0079] All patents and publications cited herein are incorporated by reference into this application in their entirety.
[0080] The words "comprise", "comprises", and "comprising" are to be interpreted inclusively rather than exclusively.

Claims

WHAT IS CLAIMED IS:
1. A method of forming a metal-containing film by a vapor deposition process, the method comprising delivering at least one precursor to a substrate, wherein the at least one precursor corresponds in structure to Formula I:
[(R)nPy]M(L)3
(Formula I) wherein:
R is independently selected from the group consisting of alkyl, alkoxy and NR1R2; R1 and R2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4; Py is pyrrolyl; M is Hf or Zr; and L is selected from the group consisting of alkyl, alkoxy and NR1R2
2. The method of Claim 1, wherein R is independently alkyl or alkoxy;
R1 and R2 are each independently hydrogen or alkyl; n is 1, 2, 3 or 4; Py is pyrrolyl; M is Hf or Zr; and L is alkoxy or NR1R2
3. The method of Claim 1, wherein M is Zr;
R is independently methyl, ethyl, propyl or butyl; n is zero, 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
4. The method of Claim 1, wherein M is Hf;
R is independently methyl, ethyl, propyl or butyl; n is zero, 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
5. The method of Claim 1, wherein M is Zr;
R is independently methyl, ethyl, propyl or butyl; n is 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
6. The method of Claim 1, wherein M is Hf;
R is independently methyl, ethyl, propyl or butyl; n is 1, 2, 3, or 4; and
L is methoxy, ethoxy, propoxy, butoxy, N(Me)2 or N(Me)(Et).
7. The method of Claim 1, wherein the at least one precursor is selected from the group consisting of:
(Py)Zr(NMe2)3; (Me2Py)Zr(NMe2)3; [(tert-butyl)2Py]Zr(NMe2)3; (Py)Hf(NMe2)3; (Me2Py)Hf(NMe2)3 ; [(tert-butyl)2Py]Hf(NMe2)3; (Py)Zr(O1Pr)3; (Me2Py)Zr(O1Pr)3; [(fer?-butyl)2Py]Zr(O1Pr)3 ; (Py)Hf(O1Pr)3; (Me2Py)Hf(O1Pr)3; and [(tert-butyl^yJHfCO'Prk.
8. The method of Claim 1, wherein the vapor deposition process is chemical vapor deposition.
9. The method of Claim 8, wherein the chemical vapor deposition is liquid injection chemical vapor deposition.
10. The method of Claim 1, wherein the vapor deposition process is atomic layer deposition.
11. The method of Claim 10, wherein the atomic layer deposition is liquid injection atomic layer deposition.
12. The method of Claim 10, wherein the atomic layer deposition is pulsed injection atomic layer deposition.
13. The method of Claim 1, wherein the at least one precursor is delivered to the substrate in pulses alternating with pulses of an oxygen source to form a metal oxide film.
14. The method of Claim 13, wherein the oxygen source is selected from H2O, O2 or ozone.
15. The method of Claim 13, further comprising delivering at least one co-precursor to form a mixed metal oxide film.
16. The method of Claim 15, wherein the mixed metal oxide film is selected from the group consisting of SrTiO3, SrZrO3, SrHfO3, LaTiO3, LaZrO3, LaHfO3, BaTiO3 and BiTiO3.
17. The method of Claim 1, further comprising delivering at least one appropriate co- reactant selected from the group consisting of hydrogen, hydrogen plasma, oxygen, air, water, ammonia, hydrazine, alkylhydrazine, borane, silane, ozone and a combination thereof.
18. The method of Claim 1, wherein the substrate is selected from the group consisting of silicon, silicon oxide, silicon nitride, tantalum, tantalum nitride, copper, ruthenium, titanium nitride, tungsten, and tungsten nitride.
19. The method of Claim 1, wherein the method is used for a memory or logic application.
20. The method of Claim 19, wherein the method is used for a DRAM or CMOS application.
21. An organometallic precursor corresponding in structure to Formula I:
[(R)nPy]M(L)3
(Formula I) wherein:
R is independently selected from the group consisting of alkyl, alkoxy and NR1R2; R1 and R2 are each independently hydrogen or alkyl; n is zero, 1, 2, 3 or 4; Py is pyrrolyl; M is Hf or Zr; and L is selected from the group consisting of alkyl, alkoxy and NR1R2.
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