Method for depositing silicon oxide film having improved quality by peald using bis(diethylamino)silane
11527400 · 2022-12-13
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Inventors
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Abstract
In a method of depositing a silicon oxide film using bis(diethylamino)silane (BDEAS) on a substrate in a reaction space by plasma-enhanced atomic layer deposition (PEALD), each repeating deposition cycle of PEALD includes steps of: (i) adsorbing BDEAS on the substrate placed on a susceptor having a temperature of higher than 400° C. in an atmosphere substantially suppressing thermal decomposition of BDEAS in the reaction space; and (ii) exposing the substrate on which BDEAS is adsorbed to an oxygen plasma in the atmosphere in the reaction space, thereby depositing a monolayer or sublayer of silicon oxide.
Claims
1. A method of depositing a silicon oxide film using bis(diethylamino)silane (BDEAS) on a substrate in a reaction space by plasma-enhanced atomic layer deposition (PEALD), each repeating deposition cycle of PEALD comprising steps of: (i) adsorbing BDEAS on the substrate placed on a susceptor having a temperature of higher than 500° C.; (ii) purging the reaction space; (iii) exposing the substrate on which BDEAS is adsorbed to an oxidizer gas in an atmosphere in the reaction space, and applying an RF power, thereby depositing a monolayer or sublayer of silicon oxide, wherein the atmosphere has an oxygen concentration of 5% to 70% by volume in a carrier gas; and (iv) purging the reaction space; wherein the oxidizer gas is fed to the reaction space continuously throughout the deposition cycle, and wherein a pressure within the reaction space is less than 1000 Pa.
2. The method according to claim 1, wherein the temperature of the susceptor is not higher than 650° C.
3. The method according to claim 1, wherein the atmosphere has a pressure of 400 Pa or less.
4. The method according to claim 1, wherein the atmosphere has an oxygen concentration of 30% to 60% by volume.
5. The method according to claim 1, wherein one or more of the (ii) purging the reaction space and the (iv) purging is conducted for less than 2.0 seconds.
6. The method according to claim 1, wherein the oxidizer gas comprises nitrogen dioxide.
7. The method according to claim 1, wherein in step (ii), oxidizer gas is fed to the reaction space at a flow rate of between 1600 and 4000 sccm, and an inert gas is fed to the reaction space at a flow rate of between 2000 and 4400 sccm.
8. The method according to claim 1, wherein the substrate comprises a trench, and wherein the silicon oxide film is deposited on the sidewalls and the bottom surface of the trench.
9. The method of claim 1, wherein the carrier gas is fed to the reaction space continuously throughout the deposition cycle, and wherein in step (i), the BDEAS is provided to the reaction space in a pulse by flowing the carrier gas through a bottle carrying the BDEAS.
10. The method of claim 1, wherein the oxygen concentration is 50% to 70% by volume.
11. The method of claim 1, wherein the oxidizer gas consists essentially of oxygen and the carrier gas.
12. The method of claim 11, wherein the carrier gas is a noble gas.
13. The method according to claim 1, wherein the substrate has a patterned step on which BDEAS is adsorbed in step (i).
14. The method according to claim 13, wherein the patterned step is a trench having an aspect ratio of 3 or higher.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other features of this invention will now be described with reference to the drawings of preferred embodiments which are intended to illustrate and not to limit the invention. The drawings are greatly simplified for illustrative purposes and are not necessarily to scale.
(2) The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
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DETAILED DESCRIPTION OF EMBODIMENTS
(11) In this disclosure, “gas” may include vaporized solid and/or liquid and may be constituted by a single gas or a mixture of gases, depending on the context. Likewise, an article “a” or “an” refers to a species or a genus including multiple species, depending on the context. In this disclosure, a process gas introduced to a reaction chamber through a showerhead may be comprised of, consist essentially of, or consist of an aminosilane precursor and an additive gas. The precursor may contain only bis(diethylamino)silane (BDEAS) or contain BDEAS as a primary precursor and one or more secondary precursor(s) which is/are either aminosilane or non-aminosilane to the extent not interfering with plasma oxidation of BDEAS to form silicon oxide. The additive gas may include a plasma-generating gas for exciting the precursor to deposit silicon oxide when RF power is applied to the additive gas. The additive gas may contain a reactant gas for oxidizing the precursor and may further contain an inert gas which may be fed to a reaction chamber as a carrier gas and/or a dilution gas to the extent not interfering with plasma oxidation forming silicon oxide. The precursor and the additive gas can be introduced as a mixed gas or separately to a reaction space. The precursor can be introduced with a carrier gas such as a rare gas. A gas other than the process gas, i.e., a gas introduced without passing through the showerhead, may be used for, e.g., sealing the reaction space, which includes a seal gas such as a rare gas. In some embodiments, the term “precursor” refers generally to a compound that participates in the chemical reaction that produces another compound, and particularly to a compound that constitutes a film matrix or a main skeleton of a film, whereas the term “reactant” refers to a compound, other than precursors, that activates a precursor, modifies a precursor, or catalyzes a reaction of a precursor, wherein the reactant may provide an element (such as O) to a film matrix and become a part of the film matrix, when RF power is applied. The term “inert gas” refers to a plasma-generating gas that excites a precursor when RF power is applied, but unlike a reactant, it does not become a part of a film matrix.
(12) In some embodiments, “a monolayer” refers to a layer one molecule thick, and “a sublayer” refers to a subunit of layer which is not necessarily a monolayer but is a layer deposited in one cycle of ALD as a subunit part of a final film. In some embodiments, “film” refers to a layer continuously extending in a direction perpendicular to a thickness direction substantially without pinholes to cover an entire target or concerned surface, or simply a layer covering a target or concerned surface. In some embodiments, “layer” refers to a structure having a certain thickness formed on a surface or a synonym of film or a non-film structure. A film or layer may be constituted by a discrete single film or layer having certain characteristics or multiple films or layers, and a boundary between adjacent films or layers may or may not be clear and may be established based on physical, chemical, and/or any other characteristics, formation processes or sequence, and/or functions or purposes of the adjacent films or layers. Further, in this disclosure, any two numbers of a variable can constitute a workable range of the variable as the workable range can be determined based on routine work, and any ranges indicated may include or exclude the endpoints. Additionally, any values of variables indicated (regardless of whether they are indicated with “about” or not) may refer to precise values or approximate values and include equivalents, and may refer to average, median, representative, majority, etc. in some embodiments. Further, in this disclosure, the terms “constituted by” and “having” refer independently to “typically or broadly comprising”, “comprising”, “consisting essentially of”, or “consisting of” in some embodiments. In this disclosure, any defined meanings do not necessarily exclude ordinary and customary meanings in some embodiments.
(13) In this disclosure, “continuously” refers to without breaking a vacuum, without interruption as a timeline, without any material intervening step, without changing treatment conditions, immediately thereafter, as a next step, or without an intervening discrete physical or chemical structure between two structures other than the two structures in some embodiments.
(14) In this disclosure, a “step” or “recess” refers to any structure having a top surface, a sidewall, and a bottom surface formed on a substrate, which may continuously be arranged in series in a height direction or may be a single step, and which may constitute a trench, a via hole, or other recesses. Further, in this disclosure, a trench is any recess pattern including a hole/via and which has, in some embodiments, a width of 10 to 50 nm (typically 15 to 30 nm) (wherein when the trench has a length substantially the same as the width, it is referred to as a hole/via, and a diameter thereof is 10 to 50 nm), a depth of 30 to 200 nm (typically 50 to 150 nm), and an aspect ratio of 3 to 20 (typically 3 to 10).
(15) In this disclosure, a SiO film includes not only SiO films, but also SiOC films, SiON films, SiOCN films, or the like, depending on the process recipe, wherein the film names are abbreviations indicating merely the film types (indicated simply by primary constituent elements) in a non-stoichiometric manner unless described otherwise.
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(17) The continuous flow of the carrier gas can be accomplished using a flow-pass system (FPS) wherein a carrier gas line is provided with a detour line having a precursor reservoir (bottle), and the main line and the detour line are switched, wherein when only a carrier gas is intended to be fed to a reaction chamber, the detour line is closed, whereas when both the carrier gas and a precursor gas are intended to be fed to the reaction chamber, the main line is closed and the carrier gas flows through the detour line and flows out from the bottle together with the precursor gas. In this way, the carrier gas can continuously flow into the reaction chamber and can carry the precursor gas in pulses by switching between the main line and the detour line.
(18) In some embodiments, the duration of “Feed” is 0.1 seconds to 3.0 seconds (preferably 0.2 seconds to 0.5 seconds).
(19) Next, in the second step (“Purge-1”), the reaction space is purged so as to remove excess BDEAS and non-adsorbed BDEAS from the surface of the substrate. The purging can be accomplished simply by continuous flows of oxidizer and carrier gas which function as a purging gas, although a separate purging gas can be used. In some embodiments, the duration of purge is 0.2 seconds to 2.0 seconds (preferably 0.3 seconds to 1.0 seconds). In some embodiments, in PEALD, by shortening a duration of purge (e.g., to a range of 0.1 seconds to 0.5 seconds), some non-adsorbed BDEAS may remain on the top surface and in the trench, and this may result in lowering film quality on the top surface and at the bottom of the trench, while improving film quality on the sidewalls to a certain degree. This may be because a shorter duration of purge leaves more BDEAS in the trench which may stay in the trench like cloud which may partially block plasma from reaching the bottom, while more plasma energy reaches the sidewalls.
(20) Next, in the third step (“RF Pulse”), BDEAS adsorbed on the substrate surface is exposed to an oxygen plasma, thereby depositing a monolayer or sublayer of silicon oxide on the substrate. In some embodiments, the period of RF power application (the period of being exposed to a plasma) is in a range of 0.2 seconds to 2.0 seconds (preferably 0.2 seconds to 1.2 seconds). The plasma exposure time can also be adjusted by changing the distance between upper and lower electrodes when conductively coupled parallel electrodes are used wherein by increasing the distance, the retention time in which the precursor is retained in the reaction space between the upper and lower electrodes can be prolonged when the flow rate of precursor entering into the reaction space is constant. In some embodiments, the distance (mm) between the upper and lower electrodes is 7.5 mm to 13 mm (preferably 7.5 mm to 10 mm). In some embodiments, RF power (W) (e.g., 13.56 MHz) for deposition is 50 W to 1000 W (preferably 200 W to 500 W) as measured for a 300-mm wafer which can be converted to units of W/cm.sup.2 for different sizes of wafers.
(21) After the third step, in the fourth step (“Purge-2”), the reaction space is purged so as to remove unreacted BDEAS and reaction by-products from the surface of the substrate. The purging can be accomplished simply by continuous flows of oxidizer and carrier gas which function as a purging gas, although a separate purging gas can be used. In some embodiments, the duration of purge is 0.1 seconds to 1.0 seconds (preferably 0.1 seconds to 0.3 seconds).
(22) The process cycle can be performed using any suitable apparatus including an apparatus illustrated in
(23) In some embodiments, in the apparatus depicted in
(24) A skilled artisan will appreciate that the apparatus includes one or more controller(s) (not shown) programmed or otherwise configured to cause the deposition and reactor cleaning processes described elsewhere herein to be conducted. The controller(s) are communicated with the various power sources, heating systems, pumps, robotics and gas flow controllers, or valves of the reactor, as will be appreciated by the skilled artisan.
(25) In some embodiments, a dual chamber reactor (two sections or compartments for processing wafers disposed close to each other) can be used, wherein a reactant gas and a noble gas can be supplied through a shared line whereas a precursor gas is supplied through unshared lines.
(26) The film having filling capability can be applied to various semiconductor devices including, but not limited to, cell isolation in 3D cross point memory devices, self-aligned Via, dummy gate (replacement of current poly Si), reverse tone patterning, PC RAM isolation, cut hard mask, and DRAM storage node contact (SNC) isolation.
EXAMPLES
(27) In the following examples where conditions and/or structures are not specified, the skilled artisan in the art can readily provide such conditions and/or structures, in view of the present disclosure, as a matter of routine experimentation. A skilled artisan will appreciate that the apparatus used in the examples included one or more controller(s) (not shown) programmed or otherwise configured to cause the deposition and reactor cleaning processes described elsewhere herein to be conducted. The controller(s) were communicated with the various power sources, heating systems, pumps, robotics and gas flow controllers or valves of the reactor, as will be appreciated by the skilled artisan.
Reference Example 1 (Thermal Stability of BDEAS)
(28) In Reference Example 1, in order to examine thermal stability of BDEAS, a Si substrate on which a native or natural oxide film having a thickness of 1.20 nm was formed was placed in the apparatus illustrated in
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Example 1 (Improvement of Film Quality at High Deposition Temperatures)
(30) A silicon oxide film was deposited on a Si substrate (having a diameter of 300 mm and a thickness of 0.7 mm) having trenches with an opening of approximately 30 nm, which had a depth of approximately 90 nm (an aspect ratio was approximately 3), by PEALD process in order to determine film quality of the film, under the conditions shown in Table 1 below (varying the deposition temperature) in the process sequence illustrated in
(31) TABLE-US-00001 TABLE 1 (numbers are approximate) Temp. setting SUS temp (° C.). See FIG. 4 Depo Pressure (Pa) 400 Electrode Gap (mm) 7.5 Feed time (s) 0.2 Purge-1 (s) 0.3 RF time (s) 1 Purge-2 (s) 0.1 RF power (W) 500 Precursor BDEAS Carrier Ar Carrier flow (slm) 2.0 Dilution Ar (slm) 2.0 Seal He (slm) 0.2 O2 (slm) 4.0 Number of cycles 500
(32) After completion of deposition of each silicon oxide film (having an average film thickness of 25 nm on the top surface), the substrate was subjected to wet etching (by dipping the substrate in a solution of dHF having a concentration of 1% for 30 seconds at 22° C.). Further, after wet etching, a cross-sectional view of each substrate with the trenches was photographed using STEM.
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Example 2 (Improvement of Film Quality with Other Parameters)
(34) A silicon oxide film was deposited on a Si substrate in the same manner as in Example 1 except the conditions shown in Table 2 below.
(35) TABLE-US-00002 TABLE 2 (numbers are approximate) Temp. UHT-6 UHT-7 UHT-8 UHT-9 UHT-10 UHT-11 setting SUS temp (° C.). 650 Depo Pressure (Pa) 400 400 1000 3000 400 400 Purge-1 (s) 0.3 2 2 2 0.3 0.3 Carrier Ar (slm) 2.0 2.0 2.0 2.0 2.0 0.4 Dilution Ar (slm) 2.0 2.0 2.0 2.0 5.6 2.0 O2 (slm) 4.0 4.0 4.0 4.0 0.4 5.6 O2/(O2 + Ar) (%) 50 50 50 50 5 70
(36) After completion of deposition of each silicon oxide film, the substrate was subjected to wet etching in the same manner as in Example 1. Further, after wet etching, a cross-sectional view of each substrate with the trenches was photographed using STEM. It should be noted that when the deposition pressure was 3,000 Pa in UHT-9, film deposition became highly abnormal and thus, wet etch evaluation of this sample was not conducted.
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(38) Also as shown in
(39) Further, as shown in
Example 3 (Improvement of Film Quality—Blanket Deposition)
(40) A silicon oxide film was deposited on a Si substrate without trenches in the same manner as in Example 1 except this was blanket deposition (not pattern deposition).
(41) After completion of deposition of each silicon oxide film, the substrate was subjected to wet etching in the same manner as in Example 1. Further, after wet etching, film properties of each silicon oxide film were evaluated in terms of average thickness, in-plane thickness uniformity, and wet etching rate.
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(43) It will be understood by those of skill in the art that numerous and various modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention are illustrative only and are not intended to limit the scope of the present invention.