Methods of etching a contact opening over a node location on a semiconductor substrate
A chemical vapor deposition method includes providing a semiconductor substrate within a chemical vapor deposition chamber. At least one liquid deposition precursor is vaporized with a vaporizer to form a flowing vaporized precursor stream. The flowing vaporized precursor stream is initially bypassed from entering the chamber for a first period of time while the substrate is in the deposition chamber. After the first period of time, the flowing vaporized precursor stream is directed to flow into the chamber with the substrate therein under conditions effective to chemical vapor deposit a layer over the substrate. A method of etching a contact opening over a node location on a semiconductor substrate is disclosed.
This patent resulted from a continuation application of U.S. patent application Ser. No. 10/278,530, filed Oct. 22, 2002, entitled “Methods of Etching a Contact Opening Over a Node Location on a Semiconductor Substrate”, naming Mark E. Jost and Chris W. Hill as inventors, the disclosure of which is incorporated by reference; which patent resulted from a divisional application of U.S. patent application Ser. No. 09/797,898, filed Mar. 1, 2001, entitled “Chemical Vapor Deposition Methods”, naming Mark E. Jost and Chris W. Hill as inventors, now U.S. Pat. No. 6,596,641, issued Jul. 22, 2003, the disclosure of which is incorporated by reference.
TECHNICAL FIELDThis invention relates to chemical vapor deposition methods and to methods of etching a contact opening over a node location on a semiconductor substrate.
BACKGROUND OF THE INVENTIONThe invention primarily grew out needs for making highly reliable, high density dynamic random access memory (DRAM) contacts, although the invention is in no way so limited. Advanced semiconductor fabrication is employing increasing vertical circuit integration as designers continue to strive for circuit density maximization. Such typically includes multi-level metalization and interconnect schemes.
Electrical interconnect techniques typically require electrical connection between metals or other conductive layers, or regions, which are present at different elevations within the substrate. Such interconnecting is typically conducted, in part, by etching a contact opening through insulating material to the lower elevation of a desired node contact, for example of a conductive layer or conductive region. The significant increase in density of memory cells and vertical integration places very stringent requirements for contact fabrication technology. The increase in circuit density has resulted in narrower and deeper electrical contact openings between layers within the substrate, something commonly referred to as increasing aspect ratio, which is the ratio of maximum opening height to minimum opening width. Increasing aspect ratios make it difficult to complete etches to desired node locations.
For example, one typical contact etch includes the etch to a substrate diffusion region formed within a semiconductive material which is received between a pair of field effect transistor gate lines. The gate lines are typically encapsulated in a silicon nitride and/or undoped silicon dioxide material. A planarized layer of borophosphosilicate glass (BPSG) is typically provided over the field effect transistors and through which a contact opening to the substrate will be etched. Further, a very thin undoped silicon dioxide layer is typically provided intermediate the BPSG layer and the underlying substrate material to shield from diffusion of the boron and phosphorus dopants from the BPSG layer into underlying substrate material. Additionally or alternately, a thin silicon nitride layer might also be provided. An antireflective layer might also be provided over the BPSG. The layers are typically masked, for example with photoresist, and a contact opening is formed through the mask over the underlying layers over the diffusion region to which contact is desired. The antireflective coating is then etched, followed by an etch conducted through the BPSG which is substantially selective to the silicon nitride layer, undoped oxide and underlying silicon substrate such that the etch is typically referred to as a substantially self-aligned contact etch. An example dry anisotropic etching chemistry for the etch includes a combination of CHF3, CF4, CH2F2 and Ar. The typical intervening undoped silicon dioxide layer between the underlying substrate and the BPSG will typically also be etched through in spite of a poor etch rate compared to BPSG, principally due to the extreme thinness of this layer. Further, if silicon nitride is used in addition or in place of the undoped silicon dioxide layer, it would typically be separately etched. At the conclusion of the etch or etches, a native oxide might grow, which could be stripped with a dilute HF solution prior to plugging the contact opening with conductive material(s).
When the aspect ratio of the contact opening being etched through the BPSG was sufficiently below 4:1, a single etch chemistry for the BPSG was typically suitable to clear the BPSG and a thin undoped silicon oxide layer all the way to the diffusion region to outwardly expose the same, assuming silicon nitride was not present. However, as the aspect ratio of the contact opening through the BPSG approached and exceeded 4:1, it was discovered in some instances that the subject chemistry, and other attempted chemistries, were not sufficient to enable clearing the doped oxide dielectric material utilizing a single chemistry and a single etching step.
These are the circumstances which motivated the invention, although the results and objectives are in no way to be perceived as claim limitations unless such are specifically provided in the accompanying claims. The invention also has applicability outside of the problems from which it spawned, with the invention only being limited by the accompanying claims as literally worded without writing limitations or interpretations into the claims from the specification or drawings, and as appropriately interpreted in accordance with the doctrine of equivalents.
SUMMARY OF THE INVENTIONThe invention comprises chemical vapor deposition methods and methods of etching a contact opening over a node location on a semiconductor substrate. In but one implementation, a chemical vapor deposition method includes providing a semiconductor substrate within a chemical vapor deposition chamber. At least one liquid deposition precursor is vaporized with a vaporizer to form a flowing vaporized precursor stream. The flowing vaporized precursor stream is initially bypassed from entering the chamber for a first period of time while the substrate is in the deposition chamber. After the first period of time, the flowing vaporized precursor stream is directed to flow into the chamber with the substrate therein under conditions effective to chemical vapor deposit a layer over the substrate.
In one implementation, a method of etching a contact opening over a node location on a semiconductor substrate includes forming a dielectric first layer over a node location. An oxide second layer having plural dopants therein is formed over the dielectric first layer. The oxide second layer has an innermost portion and an outer portion. The outer portion has a higher concentration of one of the dopants than any concentration of the one dopant in the innermost portion. Using a single dry etching chemistry, a contact opening is etched into the outer and innermost portions of the oxide second layer to proximate the dielectric first layer over the node location. Etching is conducted into the dielectric first layer through the contact opening to proximate the node location.
In one implementation, a method of etching a contact opening over a node location on a semiconductor substrate includes forming a dielectric first layer over a node location. An oxide second layer having plural dopants therein is formed over the dielectric first layer. The oxide second layer has an innermost portion and an outer portion. The innermost portion has a higher concentration of one of the dopants than any concentration of the one dopant in the outer portion. Using a single dry etching chemistry, a contact opening is etched into the outer and innermost portions of the oxide second layer to proximate the dielectric first layer over the node location. Etching is conducted into the dielectric first layer through the contact opening to proximate the node location.
Other implementations are contemplated.
BRIEF DESCRIPTION OF THE DRAWINGSPreferred embodiments of the invention are described below with reference to the following accompanying drawings.
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
The invention comprises a chemical vapor deposition method. The invention also comprises a method of etching a contact opening over a node location on a semiconductor substrate.
Substrate 12 comprises a pair of field effect transistor gate constructions 14 and 16 having a diffusion region 18 formed therebetween in semiconductive material of substrate 10/12. In this example, diffusion region 18 constitutes a node location to which electrical connection is ultimately desired. Various dielectric and conductive layers of constructions 14 and 16 are not specifically designated as not being particularly relevant to the invention. In the preferred embodiments, gate constructions 14 and 16 include outermost insulative dielectric regions whereby a substantially self aligned contact etch can be made through an overlying insulative layer to region 18 without exposing conductive material of the gates in the event of some mask misalignment. Exemplary materials are as described above where the overlying layer will be BPSG.
Referring to
Semiconductor substrate 10 is provided within a chemical vapor deposition chamber for formation of a first dielectric layer 22 (
The description proceeds with that of only an exemplary preferred embodiment of depositing a doped oxide layer over substrate 10. In this but one exemplary preferred embodiment, the outermost layer of the preferred dielectric mass being deposited will comprise borophosphosilicate glass. Thereby, feed stream 64 feeds a first liquid deposition precursor, for example tetraethylorthosilicate (TEOS). Line 65 feeds an exemplary second liquid deposition precursor of triethylphosphate. The phosphorous in such material constitutes an exemplary first dopant to at some point be provided in the dielectric mass being formed. Line 66 feeds an exemplary third liquid deposition precursor of triethylborate. The boron in such precursor constitutes an exemplary second precursor different from the first for provision at some point within the dielectric mass being fabricated. In this example, line 80 constitutes an exemplary input line for a fourth vapor precursor, here in this preferred embodiment to include one or a combination of O2 and O3.
In a specific and preferred embodiment, the liquid precursor flowing in stream 64 to vaporizer V1 is vaporized to form a flowing vaporized precursor within stream 67 and stream 70. Valve 76 is preferably initially totally closed to line 72 and is preferably initially totally opened to line 74. Thereby, the flowing vaporized precursor in stream 70 is initially bypassed from entering chamber 60 and allowed to flow out exhaust stream 84 for some first period of time while substrate 10 is within deposition chamber 60. A preferred reason for initially bypassing flow of the precursor to chamber 60 is that the flow of the flowing precursor from the vaporizer is typically not initially at a desired steady state. Preferably, the period of time is selected to be effective to achieve steady state flow of the vaporized precursor at the conclusion of the period. Accordingly, in the typical embodiment, flow of the vaporized precursor during the first period of time is not steady state during all of such first period.
In conjunction with the above flowing first vaporized precursor, the second liquid deposition precursor flowing in line 65 is preferably caused to be vaporized by vaporizer V2 to form a flowing second vaporized precursor, in this example comprising the phosphorous dopant, within line 68 and thereby also within combined flowpath 70 with the flowing first vaporized precursor from line 67. The flowing first and second vaporized precursors are thereby initially bypassed within combined flowpath 70 from entering chamber 60 for a period of time while substrate 10 is within deposition chamber 60. The preferred desire and effect is to achieve steady state flow at the desired deposition conditions of the first and second precursors within line 70 prior to flowing the same to deposition chamber 60. The period of time to achieve stabilization is typically less than 10 seconds. Preferably after achieving a steady state flow, the first and second vaporized precursors are directed within combined flowpath 70 to flow into chamber 60 with the substrate therein under conditions effective to chemical vapor deposit first dielectric layer 22 (
Such conditions in the illustrated preferred example also include suitable flow of an oxygen/ozone mixture through line 80 into chamber 60. By way of example only, preferred flow rates from line 64 to vaporizer V1 include a TEOS flow at 600 mg/min and a flow within line 80 of 12% O3/88% O2 by weight at 3 standard liters/min. Such is considered in the context of a single wafer chamber 60 having a volume of approximately 6 liters. An exemplary pressure during deposition within chamber 60 is 200 Torr, with the wafer chuck temperature within chamber 60 preferably being maintained at about 530□C. An exemplary period of time to achieve steady state flow prior to directing the first vaporized precursor to the chamber is 10 seconds or less. A specific exemplary flow for triethylphosphate within line 65 is at 100 mg/min. A preferred result is to achieve approximately 4% to 12% phosphorous doping within layer 22. An exemplary preferred thickness for layer 22 is from about 50 Angstroms to about 500 Angstroms, with from about 100 Angstroms to about 300 Angstroms being preferred, and from about 200 Angstroms to 275 Angstroms being even more preferred.
At the conclusion of such processing, preferably any flow of ozone within line 80 is ceased, and a pure oxygen or inert gas caused to flow therethrough. Further preferably, valve 76 is preferably totally closed to line 72 and valve 76 is preferably totally opened to line 74, once again causing flowing vaporized precursor from lines 67 and 68 into line 70, into line 74 and out exhaust line 84.
In this embodiment, layer 22 is preferably as shown and described directly deposited on underlying dielectric layer 20. In this just described embodiment, no vaporized precursor flows from vaporizer V3 to chamber 60 during deposition of layer 22. Further, no other source of the second dopant is provided to chamber 60 in the depicted preferred example. Further, the concentration of the second dopant (in this example, boron) in first dielectric layer 22 is thereby substantially zero (meaning below detectable levels) at least at this point in the preferred embodiment process. Alternately, some third vaporized precursor might be caused to flow to chamber 60 during the first dielectric depositing, with the concentration of the second dopant in first dielectric layer 22 at this point in the process being at some desired measurable level. Typical prior art BPSG layers comprise from 2%-5% boron and from 4%-12% phosphorous, with the remainder constituting SiO2 (by weight). In this particular example, where borophosphosilicate glass is being formed either in
Preferably essentially simultaneously with the conclusion of layer 22 formation, the flowing first and second vaporized precursors within combined flowpath 70 are bypassed from entering chamber 60 while substrate 10 is therewithin. Such preferably occurs by switching valve 76 completely closed to line 72 and completely opened to line 74, all while continuing operation of vaporizers V1 and V2. Preferably essentially simultaneously therewith, a third deposition precursor, in this example in the form of triethylborate, flowing in line 66 is vaporized in vaporizer V3 forming a flowing third vaporized precursor comprising a second dopant (here, boron), different from the first dopant, in line 69. The flowing third vaporized precursor in line 69 is combined with the flowing bypassed first and second vaporized precursors in combined flowpath 70, with the combined flowing first, second and third vaporized precursors therewithin being bypassed to exhaust 84 and thereby prevented from entering chamber 60 for a period of time while substrate 10 is within chamber 60. As with the above-described processing, such period of time is preferably suitable to achieve steady state flow of the combined precursors, and will typically be less than 10 seconds. During the time where deposition does not occur within chamber 60, the flow of gasses from line 80 is preferably again changed to be pure O2 or an inert gas. In the preferred described embodiment, flows are preferably as described above, with an exemplary flow of the triethylborate in line 66 being at 100 mg/min.
Preferably after the steady state has been achieved, the combined flowing first, second and third vaporized precursors within combined flowpath 70 are directed to flow into chamber 60 with substrate 10 therein under conditions effective to chemical vapor deposit a second dielectric layer 24 (
The illustrated
The
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When layer 20 comprises nitride or some other material which is not sufficiently etched by the single etching chemistry for layer 25, layer 20 can be suitably dry or wet etched to effectively outwardly expose node location 18.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
Claims
1-3. (canceled)
4. A chemical vapor deposition method comprising:
- providing a semiconductor substrate within a chemical vapor deposition chamber;
- vaporizing a first liquid deposition precursor with a first vaporizer forming a flowing first vaporized precursor;
- vaporizing a second deposition precursor with a second vaporizer forming a flowing second vaporized precursor;
- bypassing at least one of the flowing first and the second precursors from entering the chamber for a first period of time while the substrate is in the deposition chamber; and
- after the first period of time, directing the at least one bypassed flowing precursor to flow into the chamber with the substrate therein.
5. The method of claim 4 comprising bypassing flowing both the first and the second precursors from entering the chamber for the first period of time while the substrate is in the deposition chamber, the directing comprising directing both the first and second precursors to flow into the chamber with the substrate therein.
6. The method of claim 4 comprising bypassing the flowing first precursor during the first period, and starting vaporizing of the second deposition precursor after said bypassing.
7. The method of claim 4 wherein the directing comprises directing the at least one bypassed flowing precursor to flow into the chamber with the substrate therein effective to chemical vapor deposit a layer on the substrate.
8. The method of claim 4 comprising bypass flowing both the first and the second precursors from entering the chamber for the first period of time while the substrate is in the deposition chamber, the directing comprising directing both the first and second precursors to flow into the chamber with the substrate therein effective to chemical vapor deposit a layer on the substrate.
9. The method of claim 4 wherein the flowing of the at least one of the first and second precursors during the first period of time is not steady state during all of said first period.
10. The method of claim 4 wherein the period of time is effective to achieve steady state flow of the at least one of the first and second precursors at conclusion of said period.
11. A chemical vapor deposition method comprising:
- providing a semiconductor substrate within a chemical vapor deposition chamber;
- vaporizing a first liquid deposition precursor with a first vaporizer forming a flowing first vaporized precursor;
- vaporizing a second liquid deposition precursor with a second vaporizer forming a flowing second vaporized precursor comprising a first dopant;
- vaporizing a third deposition precursor with a third vaporizer forming a flowing third vaporized precursor comprising a second dopant different from the first dopant;
- directing the flowing first vaporized precursor and the flowing second vaporized precursor to flow into the chamber with the substrate therein under conditions effective to chemical vapor deposit a first layer comprising the first dopant over the substrate; and
- after depositing the first layer, flowing the vaporized third precursor into the chamber while flowing the first vaporized precursor and the second vaporized precursor into the chamber with the substrate therein under conditions effective to chemical vapor deposit a second layer over the substrate comprising the first and second dopants, the second layer comprising a greater concentration of the second dopant than any concentration of the second dopant in the first layer.
12. The method of claim 11 comprising depositing the first layer to a thickness of from about 50 Angstroms to about 500 Angstroms.
13. The method of claim 11 comprising depositing the first layer to a thickness of from about 100 Angstroms to about 300 Angstroms.
14. The method of claim 11 wherein vaporizing of the third precursor starts after depositing the first layer.
15. The method of claim 11 wherein no third vaporized precursor flows to the chamber during the first layer depositing.
16. The method of claim 11 wherein no third vaporized precursor flows to the chamber during the first layer depositing, with the concentration of the second dopant in the first layer being substantially zero.
17. The method of claim 11 wherein some third vaporized precursor flows to the chamber during the first layer depositing, with the concentration of the second dopant in the first layer being at some desired measurable value.
18. The method of claim 11 comprising flowing another vapor precursor to the chamber during depositing at least one of the first and second layers.
19. The method of claim 11 comprising combining the vaporized first and second precursors prior to flowing them to the chamber to chemical vapor deposit the first layer.
20. The method of claim 11 comprising combining the vaporized first, second, and third precursors prior to flowing them to the chamber to chemical vapor deposit the second layer.
21. The method of claim 11 comprising stopping flow of the first and second vaporized precursors to the chamber intermediate the chemical vapor depositing of the first and second layers.
22. The method of claim 11 comprising continuing to vaporize the first and second precursors while stopping flow of the first and second vaporized precursors to the chamber intermediate the chemical vapor depositing of the first and second layers.
23. The method of claim 11 comprising bypassing flow of the first and second vaporized precursors to the chamber prior to the directing.
24. The method of claim 11 comprising bypassing flow of the first and second vaporized precursors to the chamber after depositing the first layer prior to depositing the second layer.
25. A chemical vapor deposition method comprising:
- providing a semiconductor substrate within a chemical vapor deposition chamber;
- providing first, second and third liquid vaporizers having respective first, second and third exiting vapor flowpaths which combine to form a combined flowpath;
- vaporizing a first liquid deposition precursor with the first vaporizer forming a flowing first vaporized precursor within the combined flowpath;
- vaporizing a second liquid deposition precursor with the second vaporizer forming a flowing second vaporized precursor comprising a first dopant within the combined flowpath with the flowing first vaporized precursor;
- initially bypassing the flowing first and second vaporized precursors within the combined flowpath from entering the chamber for a first period of time while the substrate is in the deposition chamber;
- after the first period of time, directing the flowing first and second vaporized precursors within the combined flowpath to flow into the chamber with the substrate therein under conditions effective to chemical vapor deposit a first layer comprising the first dopant over the substrate;
- after depositing the first layer, second bypassing the flowing first and second vaporized precursors within the combined flowpath from entering the chamber while the substrate is in the deposition chamber;
- vaporizing a third deposition precursor with the third vaporizer forming a flowing third vaporized precursor comprising a second dopant different from the first dopant, and combining the flowing third vaporized precursor with the flowing second bypassed first and second vaporized precursors in the combined flowpath and bypassing the combined flowing first, second and third vaporized precursors within the combined flowpath from entering the chamber for a second period of time while the substrate is in the deposition chamber; and
- after the second period of time, directing the combined flowing first, second and third vaporized precursors within the combined flowpath to flow into the chamber with the substrate therein under conditions effective to chemical vapor deposit a second layer comprising the first and second dopants over the first layer, the second layer comprising a greater concentration of the second dopant than any concentration of the second dopant in the first layer.
26. The method of claim 25 flowing a fourth precursor to the chamber separate from the combined flowpath during forming of each of the first and second layers.
27. The method of claim 25 comprising chemical vapor depositing the second layer onto the first layer.
28. The method of claim 25 wherein no third vaporized precursor flows to the chamber during the first layer depositing.
29. The method of claim 25 wherein no third vaporized precursor flows to the chamber during the first layer depositing, with the concentration of the second dopant in the first layer being substantially zero.
30. The method of claim 25 wherein some third vaporized precursor flows to the chamber during the first layer depositing, with the concentration of the second dopant in the first layer being at some desired measurable value.
31. The method of claim 25 wherein the flowing of the vaporized precursors during the first and second periods of time is not steady state during all of said first and second periods.
32. The method of claim 25 wherein the first and second periods of time are effective to achieve steady state flow of the vaporized precursors at conclusion of said respective periods.
33. The method of claim 25 comprising depositing the first layer to a thickness of from about 50 Angstroms to about 500 Angstroms.
34. The method of claim 25 comprising depositing the first layer to a thickness of from about 100 Angstroms to about 300 Angstroms.
35-72. (canceled)
73. A chemical vapor deposition method comprising:
- providing a semiconductor substrate within a chemical vapor deposition chamber;
- providing first and second liquid vaporizers having respective first and second flowpaths which combine to form a combined flowpath;
- vaporizing a first liquid deposition precursor with the first vaporizer forming a flowing first vaporized precursor within the combined flowpath;
- vaporizing a second liquid deposition precursor with the second vaporizer forming a flowing second vaporized precursor within the combined flowpath with the flowing first vaporized precursor;
- bypassing the flowing first and second vaporized precursors within the combined flowpath from entering the chamber for a first period of time while the substrate is in the deposition chamber; and
- after the first period of time, directing the flowing first and second vaporized precursors within the combined flowpath to flow into the chamber with the substrate therein under conditions effective to chemical vapor deposit a layer over the substrate.
74. The method of claim 73 wherein the flowing of the first and second vaporized precursors within the combined flowpath during the first period of time is not steady state during all of said first period.
75. The method of claim 73 wherein the period of time is effective to achieve steady state flow of the first and second vaporized precursors within the combined flowpath at conclusion of said period.
76. A chemical vapor deposition method comprising:
- providing a semiconductor substrate within a chemical vapor deposition chamber;
- providing first and second liquid vaporizers having respective first and second flowpaths which combine to form a combined flowpath;
- vaporizing a first liquid deposition precursor with the first vaporizer forming a flowing first vaporized precursor within the combined flowpath;
- vaporizing a second liquid deposition precursor with the second vaporizer forming a flowing second vaporized precursor comprising a dopant within the combined flowpath with the flowing first vaporized precursor;
- bypassing the flowing first and second vaporized precursors within the combined flowpath from entering the chamber for a first period of time while the substrate is in the deposition chamber; and
- after the first period of time, directing the flowing first and second vaporized precursors within the combined flowpath to flow into the chamber with the substrate therein under conditions effective to chemical vapor deposit a layer comprising the dopant over the substrate.
77. The method of claim 76 wherein the flowing of the first and second vaporized precursors within the combined flowpath during the first period of time is not steady state during all of said first period.
78. The method of claim 76 wherein the period of time is effective to achieve steady state flow of the first and second vaporized precursors within the combined flowpath at conclusion of said period.
Type: Application
Filed: Sep 28, 2005
Publication Date: Feb 2, 2006
Inventors: Mark Jost (Boise, ID), Chris Hill (Boise, ID)
Application Number: 11/237,433
International Classification: H01L 21/302 (20060101); H01L 21/461 (20060101);