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TWI463566B - 低溫氧化矽轉換 - Google Patents

低溫氧化矽轉換 Download PDF

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TWI463566B
TWI463566B TW101112832A TW101112832A TWI463566B TW I463566 B TWI463566 B TW I463566B TW 101112832 A TW101112832 A TW 101112832A TW 101112832 A TW101112832 A TW 101112832A TW I463566 B TWI463566 B TW I463566B
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ruthenium
nitrogen
hydrogen
substrate
precursor
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TW201248723A (en
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梁靜美
英格爾尼汀Ｋ
洪淑元
帕特安札那Ｍ
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應用材料股份有限公司
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    • H10P14/6334—
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/34—Nitrides
    • C23C16/345—Silicon nitride
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/56—After-treatment
    • H10P14/668—
    • H10P14/69215—
    • H10P95/90—

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  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Formation Of Insulating Films (AREA)
  • Chemical Vapour Deposition (AREA)

Description

低溫氧化矽轉換 【交互參照之相關申請案】
本申請案主張西元2011年4月20日提出申請、名稱為「低溫氧化矽轉換(LOW TEMPERATURE SILICON OXIDE CONVERSION)」的美國臨時專利申請案第61/477,515號的權益，該臨時專利申請案全文為所有目的以引用方式併入本文中。
本發明係關於半導體處理技術。
自數十年前引用以來，半導體裝置幾何形狀尺寸已大幅微縮。現代半導體製造設備例行製造具45奈米(nm)、32 nm和28 nm特徵結構尺寸的裝置，並開發及使用新設備來製造更小幾何形狀的裝置。特徵結構尺寸微縮導致裝置上的結構特徵結構空間尺寸縮小。裝置上的縫隙與溝槽寬度變窄成一個點，其中縫隙深度與寬度的深寬比變得太高，因而難以用介電材料填充縫隙。沉積介電材料易於縫隙完全填充前堵塞頂部，以致在縫隙中間產生孔隙或裂縫。
多年來，已開發許多技術來避免介電材料堵塞縫隙頂部或「治癒」已形成的孔隙或裂縫。一方式係始於高流 動性前驅物材料，該前驅物材料以液相形式塗抹於旋轉基板表面(例如SOG沉積技術)。該等流動性前驅物可流入及填充很小的基板縫隙，又不會形成孔隙或細縫。然一旦沉積，該等高流動性材料即需硬化成固態介電材料。
在許多情況下，硬化包括熱處理以自沉積材料移除碳與羥基而留下固態介電質，例如氧化矽。不幸的是，分離碳與羥基物種通常會在硬化介電質內留下孔洞，因而降低最終材料的品質。此外，硬化介電質的體積亦易收縮，以致在介電質與周圍基板間界面留下裂痕與空間。在一些情況下，硬化介電質的體積減少40%或以上。
旋塗式介電質(SOD)亦可用於流入圖案化基板上的特徵結構。該材料通常從含矽、氮與氫的矽氮烷型膜轉換成氧化矽。含矽、氮與氫膜通常在高溫、含氧環境下轉換成氧化矽。環境中的氧取代氮與氫而產生氧化矽膜。就一些電路架構而言，高溫暴露氧環境會破壞下方膜。基於此考量，導致在製造製程流程期間需保留在「熱預算」內。熱預算考量大大使SOD限制在併入下方氮化矽層的製程流程(例如DRAM應用)，氮化矽層可保護下方特徵結構不被氧化。
因此，需要新沉積製程和材料來形成介電材料至結構基板上，又不需在含氧環境中進行高溫處理。本申請案滿足上述和其他需求。
茲描述形成氧化矽層的方法。該方法先利用自由基組分化學氣相沉積(CVD)，沉積含矽-氮-氫(聚矽氮烷)膜。在低基板溫度下讓聚矽氮烷膜暴露於濕氣，以將聚矽氮烷膜轉換成氧化矽。亦可把聚矽氮烷膜浸入兼具氧與氫的液體中，例如水、過氧化氫及/或氫氧化銨。該等轉換技術可個別或依序結合使用。本文所述轉換技術可加速轉換、產生值得製造的膜及免除高溫氧化處理要求。臭氧處理可早於轉換技術進行。
本發明實施例包括形成氧化矽層至基板上的方法。方法包括形成含矽-氮-氫層。形成含矽-氮-氫層包括：使未激發前驅物流入遠端電漿區，以產生自由基前驅物；在無電漿基板處理區中，結合含矽前驅物與自由基前驅物；及沉積含矽-氮-氫層至基板上。方法進一步包括在含臭氧大氣中，固化含矽-氮-氫層，以將含矽-氮-氫層轉換成含矽-氧層。方法進一步包括讓含矽-氧層暴露於相對濕度至少50%的潮濕大氣，以將含矽-氧層轉換成氧化矽層。
本發明實施例包括形成氧化矽層至基板上的方法。方法包括形成含矽-氮-氫層。形成含矽-氮-氫層包括：使未激發前驅物流入遠端電漿區，以產生自由基前驅物；在無電漿基板處理區中，結合含矽前驅物與自由基前驅物；及沉積含矽-氮-氫層至基板上。方法進一步包括在 含臭氧大氣中，固化含矽-氮-氫層，以將含矽-氮-氫層轉換成含矽-氧層。方法進一步包括把含矽-氧層浸入包含氧與氫的液體溶液中，以將含矽-氧層轉換成氧化矽層。
以下敘述將提出部分附加實施例和特徵，且熟諳此技術者在檢閱說明書或實行本發明後，在某種程度上將變得更清楚易懂。利用說明書所述工具、組合和方法，將能理解及達到本發明的特徵和優點。
茲描述形成氧化矽層的方法。該方法先利用自由基組分化學氣相沉積(CVD)，沉積含矽-氮-氫(聚矽氮烷)膜。在低基板溫度下讓聚矽氮烷膜暴露於濕氣，以將聚矽氮烷膜轉換成氧化矽。亦可把聚矽氮烷膜浸入兼具氧與氫的液體中，例如水、過氧化氫及/或氫氧化銨。該等轉換技術可個別或依序結合使用。本文所述轉換技術可加速轉換、產生值得製造的膜及免除高溫氧化處理要求。臭氧處理可早於轉換技術進行。
茲發現讓自由基組分CVD之含矽-氮-氫膜暴露於潮濕大氣可加速氧化矽轉換完成，此可由傅立葉轉換紅外線光譜(FTIR)測定。未暴露於潮濕大氣時，膜的性質和化學計量會隨時間變化。膜性質改變會使製造製程複雜化。茲發現如本文所述讓膜暴露於濕氣可快速又可再現地使膜性質達穩態，此特徵在於FTIR測定顯示膜基本上 無氮含量。進一步發現以除自由基組分CVD外的方法沉積的聚矽氮烷膜無法達成穩態氧化矽膜。此觀察結果可能係因如藉由混合自由基前驅物與含矽前驅物來沉積含矽-氮膜而製得更空曠的網狀物所致。空曠網狀物容許濕氣穿透到膜內更深處。如此可擴大基板方向的氧化物轉換。茲發現在不藉助較高溫氧大氣處理的情況下，讓矽氮烷膜暴露於濕氣可產生氧化矽。避免高溫氧處理預期可保留在氧化預算內，進而增進裝置良率和效能。亦發現讓含矽-氮-氫膜暴露於含氧與氫的液體中可在低溫下使膜轉換成氧化矽。
茲發現依據本文所述方法轉換成氧化矽的許多自由基組分CVD膜呈現當基板暴露於典型潔淨室大氣時不會釋出氣體的性質。現將描述形成氧化矽層的方法和系統相關的額外細節。
示例性氧化矽形成製程
第1圖為根據本發明實施例，製造氧化矽膜的方法100的選定步驟流程圖。方法100包括提供含矽前驅物至基板處理區(操作102)。在實施例中，含矽前驅物未經電漿激發，故前驅物可完整無缺的進入基板處理區。接著，僅由不久待引用的自由基前驅物提供激發。在本發明實施例中，含矽前驅物可含一些碳，或者含矽前驅物可不含碳。含矽前驅物例如為含矽-氮前驅物、含矽-氫前驅物或含矽-氮-氫前驅物和其他矽前驅物類型。如以下詳細說明，缺碳可降低沉積膜收縮率。除無碳外，含矽前 驅物還可為無氧。缺氧會造成由前驅物形成的含矽-氮層有較低濃度的矽醇(Si-OH)基。沉積膜有過量矽醇基元將導致孔隙度和收縮率在自沉積層移除羥基(-OH)基元的後沉積步驟期間提高。
無碳之矽前驅物特例可包括矽烷胺，例如H2 N(SiH3 )、HN(SiH3 )2 與N(SiH3 )3 和其他矽烷胺。在不同實施例中，矽烷胺的流率可為大於或約200標準毫升每分鐘(sccm)、大於或約300 sccm或大於或約500 sccm。在此提及的所有流率係參照雙腔室基板處理系統。單一晶圓系統需要該等流率的一半，其他晶圓尺寸則需按處理面積縮放流率。矽烷胺可與附加氣體混合，附加氣體可當作載氣、反應氣體或二者。示例性附加氣體包括H2 、N2 、NH3 、He與Ar和其他氣體。無碳之含矽前驅物例子亦可包括甲矽烷(SiH4 )，SiH4 可單獨或與其他含矽(例如N(SiH3 )3 )、氫(例如H2 )及/或氮(例如N2 、NH3 )之氣體混合使用。無碳之含矽前驅物亦可包括二矽烷、三矽烷、甚至更高級矽烷和氯化矽烷，上述物質可單獨或互相結合或結合前述無碳之含矽前驅物使用。
亦提供自由基前驅物至基板處理區(操作104)。自由基前驅物描繪在基板處理區外的電漿激發區由任何穩定物種(惰性或反應性)產生的電漿流出物。自由基前驅物可為含氮自由基前驅物，含氮自由基前驅物在此稱作氮自由基前驅物。氮自由基前驅物為含氮自由基前驅物，含氮自由基前驅物係在基板處理區外由更穩定的氮 前驅物產生。穩定前驅物在此稱作未激發前驅物，藉以表示前驅物尚未穿過電漿。可在腔室電漿區或在處理腔室外的遠端電漿系統(RPS)中活化含NH3 、聯氨(N2 H4 )及/或N2 的穩定氮前驅物化合物，以形成氮自由基前驅物，接著將氮自由基前驅物輸送到基板處理區而激發含矽前驅物。在不同實施例中，穩定氮前驅物亦可為包含NH3 與N2 、NH3 與H2 、NH3 與N2 與H2 和N2 與H2 的混合物。聯氨亦可用來代替或結合NH3 和含N2 與H2 的混合物。在不同實施例中，穩定氮前驅物的流率可為大於或約300 sccm、大於或約500 sccm或大於或約700 sccm。在腔室電漿區中產生的氮自由基前驅物可為．N、．NH、．NH2 等之一或更多者，且還可伴有電漿中形成的離子化物種。氧源亦可結合遠端電漿中更穩定的氮前驅物，以預先使膜充滿氧，同時降低流動性。氧源可包括O2 、H2 O、O3 、H2 O2 、N2 O、NO或NO2 之一或更多者。
在採用腔室電漿區的實施例中，氮自由基前驅物係在隔開沉積區的基板處理區區段中產生，前驅物於沉積區混合及反應而沉積含矽-氮層至沉積基板(半導體晶圓)上。氮自由基前驅物亦可伴隨載氣，例如氫氣(H2 )、氮氣(N2 )、氦氣等。生成含矽-氮-氫層期間與低溫臭氧固化期間，基板處理區在此描述成「無電漿」。「無電漿」未必意指該區缺乏電漿。腔室電漿區中的電漿邊界很難界定，且可能經由噴灑頭的孔徑超出基板處理區。至於誘導耦合電漿，則可直接於如基板處理區內開始少量離 子化。另外，可在基板處理區中產生低強度電漿，又不會消除成形膜的流動性本質。產生氮自由基前驅物時，造成電漿的離子密度比腔室電漿區低的所有原因未脫離本文所述「無電漿」的範圍。
在基板處理區中，無碳之矽前驅物與氮自由基前驅物混合及反應而沉積含矽-氮-氫膜至沉積基板上(操作106)。在實施例中，可使用一些配方組合來共形沉積該沉積含矽-氮-氫膜。在其他實施例中，不像習知氮化矽(Si3 N4 )膜沉積技術，該沉積含矽-氮-氫膜具流動性。形成期間具流動性本質能使膜在固化前流入窄特徵結構。
含矽-氮-氫膜中的氮源自自由基前驅物或未激發前驅物(或二者)。在一些實施例中，無碳之含矽前驅物為實質無氮。然在其他實施例中，無碳之含矽前驅物和氮自由基前驅物含有氮。在第三種實施例中，自由基前驅物為實質無氮，含矽-氮-氫層中的氮由無碳之含矽前驅物供應。如此，自由基前驅物在此可稱作「氮及/或氫自由基前驅物」，此意指前驅物含有氮及/或氫。類似地，流入電漿區而形成氮及/或氫自由基前驅物的前驅物可稱作含氮及/或氫前驅物。此命名法可應用到所述各實施例。在實施例中，含氮及/或氫前驅物包含氫氣(H2 )，氮及/或氫自由基前驅物包含．H等。
回溯第1圖所示特例，含矽-氮-氫膜的流動性起因於將氫自由基前驅物與無碳之含矽前驅物混合所引起的各 種性質。該等性質包括沉積膜的大量氫組分及/或存有短鏈聚矽氮烷聚合物。在成膜期間及之後，該等短鏈成長及網佈形成更緻密的介電材料。例如，沉積膜可具有矽氮烷型、Si-NH-Si主幹(即無碳之Si-N-H膜)。當含矽前驅物與自由基前驅物均為無碳時，該沉積含矽-氮-氫膜亦實質無碳。當然，「無碳」未必意指膜甚至缺少微量碳。前驅物材料可能存在碳污染而進入該沉積含矽-氮前驅物。然該等碳雜質量遠比在具碳基元的矽前驅物(例如TEOS、TMDSO等)中發現的碳量少。
沉積含矽-氮-氫層後，在臭氧中固化沉積基板。固化階段涉及讓含矽-氮-氫層暴露於含臭氧大氣(操作108)。在實施例中，於基板處理區外產生臭氧並使臭氧流入基板處理區。在本發明的不同實施例中，可以或可不施加電漿功率至基板處理區，以進一步激發臭氧大氣。在實施例中，缺乏電漿可避免產生氧原子，氧原子會關閉近表面網狀物及阻止次表面氧化。不僅表面附近會減少氮及增加氧，又因較穩定臭氧能穿透敞開的矽-氮-氫層網狀物，故次表面區也會減少氮及增加氧。在實施例中，隨後施加電漿至基板處理區，以於另一臭氧固化階段激發臭氧大氣。
接著，描述應用到固化操作的各種參數。沉積基板可留在基板處理區進行固化，或者基板可傳送到引用含臭氧大氣的不同腔室。在不同實施例中，任一/二階段的基板固化溫度可為低於或約300℃、低於或約250℃、低於 或約225℃或低於或約200℃。在不同實施例中，基板溫度可為高於或約室溫(25℃)、高於或約50℃、高於或約100℃、高於或約125℃或高於或約150℃。根據所述附加實施例，任何上限可結合任何下限而構成附加基板溫度範圍。在所述實施例中，固化操作期間臭氧進入基板處理區的流率(只有臭氧貢獻)可為大於500 sccm、大於1標準升每分鐘(slm)或大於2 slm。在所述實施例中，固化操作期間的臭氧分壓可為大於或約20托耳、大於或約30托耳、大於或約50托耳或大於或約100托耳。
固化操作可將含矽-氮-氫層改質成含矽-氧層。藉由讓含矽-氧層暴露於潮濕環境，以將含矽-氧層轉換成氧化矽(操作110)。在所述實施例中，可在用以固化的相同區域中提供潮濕環境，或者可把基板移到分離處理站。在本發明實施例中，潮濕環境的相對濕度可大於50%、大於60%、大於70%、大於75%、大於80%或大於85%。在實施例中，基板溫度可為室溫(25℃)至約100℃、約40℃至約95℃、約50℃至約90℃、約60℃至約90℃或約70℃至約90℃。在本發明實施例中，濕氣處理時間可少於2分鐘、少於5分鐘、少於10分鐘、少於30分鐘或少於1小時。
臭氧固化操作通常係在比濕氣處理高的基板溫度下進行。在實施例中，由於在相同區域內準確調整低溫有點困難，故可在個別腔室/站進行固化操作和濕氣處理。把所述低溫濕氣處理包括在內將不需進行高溫氧大氣退火 (例如約400℃或更高)。在本發明實施例中，固化操作結合濕氣處理可完成氧化矽轉換製程。在其他實施例中，只以濕氣處理來進行轉換製程。在任一情況下，去除高溫氧處理容許在不氧化下層的情況下進行轉換製程。缺少在氧大氣中進行高溫退火能使積體電路製造者保留在氧化預算內。去除較高溫氧退火處理可增進積體電路裝置的良率和效能。雖然本發明已排除氧化退火，但在實施例中，仍可包括高溫惰性退火，以密實氧化矽膜。在惰性環境中進行高溫退火將計及熱預算，但不算在更特定的氧化預算，各預算被認為與特殊製程流程有關。
固化操作的含臭氧大氣和濕氣處理的濕氣含量分別提供氧，以將含矽-氮-氫膜轉換成氧化矽(SiO2 )膜。利用傅立葉轉換紅外線光譜(FTIR)，分析Si-O、Si-OH和Si-N鍵的濃度。茲發現僅在臭氧固化操作後，峰和相關濃度會隨時間變化。膜的釋出性質將複雜化製造製程流程。在實施例中，先經臭氧固化、接著經濕氣處理後，FTIR峰不會隨時間發展。
現參照第2圖，第2圖為根據本發明實施例，於基板縫隙中形成氧化矽膜的方法200的另一選定步驟流程圖。基板可具有複數個縫隙供裝置部件(例如電晶體)的間隔和結構形成於基板上。縫隙的高度與寬度定義高度與寬度(即H/W)的深寬比(AR)，AR明顯大於1：1(例如5：1或以上、6：1或以上、7：1或以上、8：1 或以上、9：1或以上、10：1或以上、11：1或以上、12：1或以上等)。在許多情況下，高AR係因範圍約90 nm至約22 nm或以下(例如小於90 nm、65 nm、50 nm、45 nm、32 nm、22 nm、16 nm等)的小縫隙寬度所致。
在基板處理區中，使含矽前驅物與自由基前驅物混合(操作204)。沉積流動性含矽-氮-氫層至基板上(操作206)。因層具流動性，故該層可填充高深寬比縫隙，又不會在填料中心附近形成孔隙或細縫。例如，沉積流動性材料較不可能在縫隙完全填充前過早堵塞縫隙頂部，以致在縫隙中間留下孔隙。
接著在固化操作(操作208)中，固化剛沉積之含矽-氮-氫層，操作208有和第1圖操作108一樣的實施例。依此可將含矽-氮-氫層轉換成含矽-氧層。
接著把基板傳送出含臭氧大氣，及把含矽-氧層浸入包含氧與氫的液體溶液中(操作210)，以完成氧化矽層轉換。在本發明實施例中，因存有液體溶液步驟，故不需在含氧環境中進一步退火。如所述，臭氧固化及把形成膜浸入液浴中可於基板上(包括基板縫隙)形成氧化矽層(操作208)。如上所述，比起以含碳前驅物形成的類似層在熱處理步驟前層中有大量碳，氧化矽層有較少孔洞和較少體積縮減。在許多情況下，宜使體積稍微適度縮小(例如約15體積%或以下)，以免後熱處理步驟填充、治癒或以其他方式消除因氧化矽收縮而於縫隙內形成的空間。在一些實施例中，溝槽中的氧化矽層為實質 無孔隙。
把固化膜浸入液浴的操作期間，液浴、基板和固化膜可維持在相同溫度。在實施例中，液浴可為室溫(25℃)至約100℃、約40℃至約95℃、約50℃至約90℃、約60℃至約90℃或約70℃至約90℃。在本發明實施例中，液浴浸沒時間可少於2分鐘、少於5分鐘、少於10分鐘、少於30分鐘、少於1小時、少於2小時或少於5小時。在本發明實施例中，茲發現一旦已如所述依序以臭氧固化及液浴處理矽-氮-氫層，即不需後續高溫氧退火。本發明人進一步發現在一些情況下，液浴足以將含矽-氧層轉換成氧化矽。達成氧化矽都不需前置臭氧固化或後續高溫氧退火。FTIR再次用來測定完成基板處理後，氧化矽膜不會顯示隨時間發展的峰高與位置。經基板處理後，當基板和膜暴露於典型潔淨室大氣時，FTIR的結果實質不變。
液體浴或溶液包含氧與氫，且可包括水、過氧化氫或氫氧化銨之一或更多者。在浸入操作210期間，把矽-氧膜浸入液體溶液中，在一些實施例中，基板係浸沒在液體溶液中。在實施例中，液體溶液可為SC1或SC2浴。液體溶液可包含去離子水、至少10%的氫氧化銨和至少10%的過氧化氫。所有百分比在此係按體積計。液體溶液可包含去離子水、至少10%的氫氯酸和至少10%的過氧化氫。其他液浴可設計成兼具氧與氫。本發明人亦發現當pH下降至酸性範圍或上升至鹼性範圍時，氧化矽轉 換速率將提高。以下將於示例性氧化矽沉積系統部分引述附加參數。
示例性氧化矽沉積系統
可用於本發明實施例的沉積腔室包括高密度電漿化學氣相沉積(HDP-CVD)腔室、電漿增強化學氣相沉積(PECVD)腔室、次大氣壓化學氣相沉積(SACVD)腔室、熱化學氣相沉積系統和其他類型的腔室。可用於本發明實施例的CVD系統特例包括CENTURA ULTIMA® HDP-CVD腔室/系統和PRODUCER® PECVD腔室/系統，該等腔室/系統皆可取自美國加州聖克拉拉市的應用材料公司(Applied Materials,Inc.)。
可偕同本發明示例性方法使用的基板處理腔室實例包括共同讓渡之美國臨時專利申請案第60/803,499號、Lubomirsky等人提出、西元2006年5月30日提出申請、名稱為「用於介電質填隙的處理腔室(PROCESS CHAMBER FOR DIELECTRIC GAPFILL)」所示及所述者，該臨時專利申請案為所有目的以引用方式併入本文中。附加示例性系統包括美國專利案第6,387,207號與第6,830,624號所示及所述者，該專利案亦為所有目的以引用方式併入本文中。
沉積系統實施例可併入更大的製造系統來製造積體電路晶片。第3圖圖示根據所述實施例，沉積、烘烤及固化腔室的系統300。在該圖中，一對前開式晶圓傳送盒(FOUP)302供應基板(例如直徑300毫米(mm)的晶 圓)，基板由機器人手臂304接收，且基板於放入晶圓處理腔室308a-f之一前，放到低壓支托區306。第二機器人手臂310用於將基板晶圓從支托區306傳送到處理腔室308a-f及回傳。
處理腔室308a-f包括一或更多個系統部件，用以沉積、退火、固化及/或蝕刻基板晶圓上的流動性介電膜。在一配置下，兩對處理腔室(例如308c-d和308e-f)用於沉積流動性介電材料至基板上，第三對處理腔室(例如308a-b)用於退火處理沉積介電質。在另一配置下，相同的兩對處理腔室(例如308c-d和308e-f)配置以沉積及退火處理基板上的流動性介電膜，第三對腔室(例如308a-b)用於UV或電子束固化沉積膜。在又一配置下，三對腔室(例如308a-f)皆配置以沉積及固化基板上的流動性介電膜。在再一配置下，兩對處理腔室(例如308c-d和308e-f)用於沉積及UV或電子束固化流動性介電質，第三對處理腔室(例如308a-b)用於退火處理介電膜。在不同實施例中，所述任一或更多個製程可於與所示製造系統分離的腔室進行。
此外，一或更多個處理腔室308a-f可配置成濕式處理腔室。該等處理腔室包括在包括濕氣的大氣中加熱流動性介電膜。故系統300的實施例可包括濕式處理腔室308a-b和退火處理腔室308c-d，以於沉積介電膜上進行濕式及乾式退火。
第4A圖為根據所述實施例的基板處理腔室400。遠端 電漿系統(RPS)410可處理氣體，氣體接著行經氣體入口組件411。氣體入口組件411內有兩個不同的氣體供應通道。第一通道412運載氣體穿過遠端電漿系統(RPS)410，第二通道413則繞過RPS 410。在所述實施例中，第一通道412用於製程氣體，第二通道413用於處理氣體。蓋子(或導電頂部)421和穿孔隔板(噴灑頭453)間顯示有絕緣環424，以允許相對噴灑頭453施加AC電位至蓋子421。製程氣體行經第一通道412而進入腔室電漿區420，並由腔室電漿區420的電漿單獨或結合RPS 410激發製程氣體。腔室電漿區420及/或RPS 410的組合物在此稱作遠端電漿系統。穿孔隔板(亦稱作噴灑頭)453隔開腔室電漿區420和噴灑頭453下方的基板處理區470。噴灑頭453容許電漿存於腔室電漿區420，以免直接激發基板處理區470的氣體，同時仍可讓激發物種從腔室電漿區420進入基板處理區470。
噴灑頭453設在腔室電漿區420與基板處理區470之間，噴灑頭453容許腔室電漿區420內產生的電漿流出物(前驅物或其他氣體的激發衍生物)穿過複數個穿孔456，穿孔456橫跨板材厚度。噴灑頭453亦具有一或更多個中空容積451，中空容積451充滿蒸汽或氣體形式的前驅物(例如含矽前驅物)，前驅物經由小孔455進入基板處理區470，但不直接進入腔室電漿區420。在此所述實施例中，噴灑頭453比穿孔456的最小直徑450的長度厚。為維持有效的激發物種濃度從腔室電漿區420 穿透基板處理區470，可形成穿孔456的較大直徑部分穿過噴灑頭453，以限制穿孔最小直徑450的長度426。在所述實施例中，穿孔456的最小直徑450的長度可和穿孔456的最小直徑一樣量級或更小。
在所示實施例中，噴灑頭453可分配(經由穿孔456)製程氣體及/或製程氣體經腔室電漿區420的電漿激發後產生的電漿流出物，製程氣體含有氧、氫及/或氮。在實施例中，經由第一通道412引入RPS 410及/或腔室電漿區420的製程氣體可含有氧氣(O2 )、臭氧(O3 )、N2 O、NO、NO2 、NH3 、包括N2 H4 的Nx Hy 、甲矽烷、二矽烷、TSA和DSA之一或更多者。製程氣體亦可包括載氣，例如氦氣、氬氣、氮氣(N2 )等。第二通道413亦可輸送製程氣體及/或載氣及/或用以自成長或剛沉積膜移除不當組分的膜固化氣體(例如O3 )。電漿流出物可包括製程氣體的離子化或中性衍生物，且在此亦可稱作氧自由基前驅物及/或氮自由基前驅物，該自由基前驅物與引用製程氣體的原子成分有關。
在實施例中，穿孔456的數量可為約60至約2000個。穿孔456可具各種形狀，但最易製作成圓形。在所述實施例中，穿孔456的最小直徑450可為約0.5 mm至約20 nm或約1 mm至約6 nm。在選擇穿孔截面形狀方面也有餘地，穿孔截面可製作成圓錐形、圓柱形或兩種形狀的組合。在不同實施例中，用以將氣體引入基板處理區470的小孔455的數量可為約100至約5000個或約 500至約2000個。小孔455的直徑可為約0.1 mm至約2 nm。
第4B圖為根據所述實施例，偕同處理腔室使用的噴灑頭453的底視圖。噴灑頭453對應第4A圖所示噴灑頭。穿孔456繪示成在噴灑頭453的底部有較大內徑(ID)，頂部則有較小ID。小孔455實質均勻分佈於噴灑頭表面、甚至在穿孔456之間，如此有助於提供比所述其他實施例更均勻地混合。
當經由噴灑頭453的穿孔456到來的電漿流出物結合經由源自中空容積451的小孔455到來的含矽前驅物時，將於基板上形成示例性膜，基板由基板處理區470內的基座(未圖示)支撐。雖然基板處理區470可裝配以支援電漿進行其他製程，例如固化，但在示例性膜成長期間，並未存有電漿。
可在噴灑頭453上方的腔室電漿區420或噴灑頭453下方的基板處理區470點燃電漿。腔室電漿區420存有電漿，以從含氮-氫氣體流入物產生氮自由基前驅物。在處理腔室的導電頂部(蓋子421)與噴灑頭453間施加AC電壓，以於沉積期間點燃腔室電漿區420的電漿，AC電壓通常處於射頻(RF)範圍。RF電源產生13.56兆赫(MHz)的RF高頻，但RF電源也可單獨或結合13.56 MHz的頻率產生其他頻率。
於第二固化階段或清潔界定基板處理區470的內面期間，當基板處理區470的底部電漿開啟時，頂部電漿將 處於低或無功率。藉由在噴灑頭453與腔室的基座或底部間施加AC電壓，可點燃基板處理區470的電漿。電漿存在時，可將清潔氣體引入基板處理區470。
基座可具熱交換通道，熱交換流體流經熱交換通道，以控制基板溫度。此構造能冷卻或加熱基板溫度，以維持較低溫度(室溫至約120℃)。熱交換流體可包含乙二醇和水。亦可利用埋置單迴路加熱元件，電阻加熱基座的晶圓支撐盤(較佳為鋁、陶瓷或上述物質的組合物)達較高溫度(約120℃至約1100℃)，加熱元件依平行同心圓形式配置成完整兩圈。加熱元件的外部可鄰接支撐盤周圍運作，內部則在半徑較小的同心圓路徑運作。加熱元件的接線穿過基座主幹。
基板處理系統受控於系統控制器。在示例性實施例中，系統控制器包括硬碟機、軟碟機和處理器。處理器含有單板電腦(SBC)、類比與數位輸入/輸出板、介面板和步進馬達控制板。CVD系統的各種零件皆符合規範板、卡籠和連接器尺寸與類型的Versa Modular European(VME)標準。VME標準亦定義具16位元資料匯流排與24位元位址匯流排的匯流排結構。
系統控制器控制沉積系統的所有動作。系統控制器執行系統控制軟體，軟體為儲存於電腦可讀取媒體的電腦程式。較佳地，媒體為硬碟機，但媒體亦可為其他類型的記憶體。電腦程式包括指定特定製程之時序、混合氣體、腔室壓力、腔室溫度、RF功率大小、晶座位置和其 他參數的指令集。其他儲存於其他記憶裝置(例如包括軟碟或其他適合驅動器)的電腦程式亦可用來指示系統控制器。
可利用系統控制器執行的電腦程式產品，施行沉積膜堆疊結構至基板上、將膜轉換成氧化矽的製程或清潔腔室的製程。電腦程式碼可以任何傳統電腦可讀取程式語言編寫，例如68000組合語言、C、C++、Pascal、Fortran或其他語言。適當的程式碼乃利用傳統文字編輯器輸入單一檔案或多個檔案，並儲存或收錄在電腦可用媒體中，例如電腦的記憶系統。若輸入碼文字為高階語言，則進行編碼，產生的編譯程式碼接著連結預先編譯之Microsoft Windows®函式庫常式的目的碼。為執行連結的編譯目的碼，系統使用者訴諸目的碼，使電腦系統載入記憶體中的編碼。CPU接著讀取及執行編碼，以進行程式識別的任務。
使用者與控制器間的介面係透過平面觸控式顯示器。在較佳實施例中為採用兩個顯示器，其一裝設於潔淨室壁面供操作員使用，另一放置於壁面後方供維修技師使用。兩個顯示器同時顯示相同的資訊，但只有一個螢幕接受輸入。為選擇特定畫面或功能，操作員觸碰觸控式顯示器的指定區域。觸碰區域改變醒目顏色或顯示新的選單或畫面，以確定操作員與觸控式顯示器間的通訊無礙。其他諸如鍵盤、滑鼠或其他點觸或通訊裝置等裝置亦可附加使用或代替觸控式顯示器，以聯繫使用者與系 統控制器。
本文使用的「基板」可為具有或不具層形成於上的支撐基板。支撐基板可為絕緣體或具各種摻雜濃度與輪廓的半導體，例如用於製造積體電路的半導體基板類型。「氧化矽」層可包括低濃度的其他元素成分，例如氮、氫、碳等。在一些實施例中，氧化矽基本上由矽與氧組成。「前驅物」一詞用於指稱參予反應以自表面移除材料或沉積材料至表面上的任何製程氣體。處於「激發態」的氣體描繪至少一些氣體分子處於振動激發、游離及/或離子化狀態的氣體。氣體(或前驅物)可為二或更多氣體(或前驅物)的組合物。「自由基前驅物」用於描繪電漿流出物(處於激發態的氣體，該氣體正退出電漿)，電漿流出物參予反應以自表面移除材料或沉積材料至表面上。「氮自由基前驅物」係含氮的自由基前驅物，「氫自由基前驅物」係含氫的自由基前驅物。「鈍氣」一詞係指當蝕刻或併入膜時不會形成化學鍵的任何氣體。示例性鈍氣包括稀有氣體，但也可包括其他氣體，只要微量(通常)陷入膜時不會形成化學鍵即可。
通篇所用「溝槽」一詞並非暗示蝕刻的幾何形狀具有大的橫向深寬比。從表面上方觀看，溝槽可呈圓形、橢圓形、多邊形、矩形或種種其他形狀。「通孔」一詞係指低深寬比溝槽，通孔可以或可不填滿金屬而構成縱向電連接。在此，共形層係指表面上大致均勻的材料層且有和表面一樣的形狀，即層表面和待覆蓋表面大致平行。 此領域的一般技術人士將理解沉積材料可能無法100%共形，故以「大致」一詞表達可接受容限。
根據上述數個實施例，熟諳此技術者將可理解，使用各種潤飾、更動和均等物皆不脫離本發明的精神。此外，一些熟知的製程和元件並未提及，以免不必要地限制本發明。因此，以上說明不應視為限制本發明的範圍。
應理解除非內文特別指明，否則提供之數值範圍到下限單位的十分之一亦明確揭示介於此範圍上限與下限的中間值。介於論述範圍內任何論述值或中間值與任何其他論述值或中間值間的較小範圍也包含在內。較小範圍的上限與下限可各自涵蓋在此範圍內或排除在外，且取決於論述範圍中特別排除的限制，本發明亦包含每一種包括較小範圍之上限及/或下限的範圍。當論述範圍包括限制之一或二者時，排除該等限制的範圍亦包括在內。
除非內文清楚指明，否則本文和後附申請專利範圍使用的單數形式「一」和「該」包括複數意涵。例如，指稱「一製程」包括複數個此類製程，指稱「該前驅物」包括指稱一或更多種前驅物和熟諳此技術者已知的均等物等。
又，本說明書和以下申請專利範圍採用的「包含」與「包括」等字詞擬明定存有所述特徵、整體、部件或步驟，但並不排除另有一或更多種其他特徵、整體、部件、步驟、動作或群組。
100、200‧‧‧方法
102、104、106、108、110、204、206、208、210‧‧‧操作
300‧‧‧系統
302‧‧‧FOUP
304、310‧‧‧機器人手臂
306‧‧‧支托區
308、308a-f‧‧‧處理腔室
400‧‧‧基板處理腔室
410‧‧‧RPS
411‧‧‧氣體入口組件
412、413‧‧‧通道
420‧‧‧腔室電漿區
421‧‧‧蓋子
424‧‧‧絕緣環
426‧‧‧長度
450‧‧‧最小直徑
451‧‧‧中空容積
453‧‧‧噴灑頭
455‧‧‧小孔
456‧‧‧穿孔
470‧‧‧基板處理區
藉由參照說明書其餘部分和圖式，可進一步瞭解本發明的本質和優點，其中各圖中相同的元件符號代表相似的部件。在一些情況下，子標記與某一元件符號有關且接在連字號後面，以表示多個類似部件之一。當指稱一元件符號而不指明現有子標記時，擬指稱所有多個類似部件。
第1圖為根據本發明實施例，製造氧化矽膜的選定步驟流程圖。
第2圖為根據本發明實施例，於基板縫隙中形成氧化矽膜的另一選定步驟流程圖。
第3圖圖示根據本發明實施例的基板處理系統。
第4A圖圖示根據本發明實施例的基板處理腔室。
第4B圖圖示根據本發明實施例的氣體分配噴灑頭。
100‧‧‧方法
102、104、106、108、110‧‧‧操作

Claims (11)

  1. 一種形成一氧化矽層至一基板上的方法，該方法包含下列操作：形成一含矽-氮-氫層，形成該含矽-氮-氫層係利用下列步驟：使一未激發前驅物流入一遠端電漿區，以產生一自由基前驅物；在一無電漿基板處理區中，結合一含矽前驅物與該自由基前驅物；以及沉積該含矽-氮-氫層至該基板上；在一含臭氧大氣中，固化該含矽-氮-氫層，以將該含矽-氮-氫層轉換成一含矽-氧層；以及讓該含矽-氧層暴露於相對濕度至少50%的一潮濕大氣，以將該含矽-氧層轉換成該氧化矽層，其中在該暴露操作期間，該基板的溫度係高於25℃且低於100℃。
  2. 如請求項1所述之方法，其中該潮濕大氣具有至少75%的相對濕度。
  3. 如請求項1所述之方法，其中在該固化操作期間，該基板的溫度係高於125℃且低於225℃。
  4. 如請求項1所述之方法，其中讓該含矽-氧層暴露於 該潮濕大氣的該操作係持續不到5小時。
  5. 如請求項1所述之方法，其中讓該含矽-氧層暴露於該潮濕大氣的該操作係持續不到2小時。
  6. 如請求項1所述之方法，其中該氧化矽層基本上由矽與氧組成。
  7. 如請求項1所述之方法，其中該含矽-氮-氫層在沉積期間具流動性。
  8. 如請求項1所述之方法，其中該基板經圖案化且具有一溝槽，該溝槽的寬度為約50奈米或以下。
  9. 如請求項1之所述方法，其中該含矽前驅物和該含矽-氮-氫層各自為無碳。
  10. 如請求項1之所述方法，其中該未激發前驅物包含聯氨(N2 H4 )、氨氣(NH3 )、氮氣(N2 )和氫氣(H2 )的至少一者。
  11. 如請求項1所述之方法，其中該含矽前驅物包含N(SiH3 )3 。
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