Patent Application
20250145448
This disclosure relates to films used in semiconductor manufacturing and, more particularly, to endcap films used in semiconductor devices.
Both integrated circuit (IC) device fabrication and micro-electromechanical systems (MEMS) fabrication make use of layers or coatings of material that are deposited on a workpiece. In some instances, the layers are deposited on a workpiece and then are subsequently removed, such as when the layer is used as a patterned masking material and then is subsequently removed after the pattern is transferred to an underlying layer. In other instances, the layers are deposited to perform a function in a device or system and remain as part of the fabricated device. There are numerous methods for depositing a thin film layer or a coating. In applications where the wear on the coating is likely to occur due to mechanical contact or fluid flow over the substrate surface on which the layer of coating is present, it is helpful to have the coating chemically bonded directly to the substrate surface via reaction of the species with the surface in order to obtain particular surface properties.
With respect to layers and coatings that are chemically bonded to the workpiece surface, an area of current interest is a combination of integrated circuitry with a mechanical system, which is referred to as a micro-electromechanical system (MEMS). Due to the nanometer size scale of some of the electrical devices formed, and the use of MEMS in applications such as the biological sciences, where the type and properties of the coating on the substrate surface is used to provide a particular functionality to the surface, a need has grown for improved methods of controlling the formation of the coating or layer on the substrate surface. Historically, these types of coatings were deposited in the liquid phase, resulting in limited film property control and loss of device yield due to capillary forces. More recently, vapor-phase deposition has been used as a way to replace liquid processing and to improve coating properties.
There is a particular interest in anti-stiction layers and coatings which are needed to enable reliable, long-term performance of the MEMS. Stiction (adhesion) of compliant micromechanical parts is one of the key reliability issues that has proven difficult to overcome. Conventionally, solution-based anti-stiction monolayers have been used. However, more recently, due to capillary stiction, particulate problems, and unsatisfactory quality, scalability, and reproducibility of the films produced by relatively lengthy wet processing, efforts are underway to develop vapor deposition methods for the anti-stiction coatings. The vacuum processing and vapor phase deposition of anti-stiction coatings, including self-assembled monolayers (SAMs) has provided higher quality films in general. An integrated vapor deposition process (including surface plasma treatment in the same chamber) typically offers better control of surface reactivity, while avoiding the potential for stiction between micromechanical parts during application of the anti-stiction coating.
Molecular vapor deposition (MVD) is a process technology that deposits ultra-thin films by vapor deposition at low temperatures on a broad spectrum of workpieces, such as semiconductor wafers or MEMS. The process can grow ultra-thin, functionalized, organic and inorganic films with higher yields and better cost efficiencies than traditional liquid deposition techniques. Such films can serve as lubricant, protective, hydrophobic, hydrophilic, biocompatible, or reactive coatings. In MEMS applications, for example, MVD films are typically used as anti-stiction coatings to improve device performance, and enhance overall device lifetime.
A previous approach for forming anti-stiction coatings on silicon wafers is dosing precursor organosilane molecules individually or co-dosing the organosilane precursors with water. In the latter case, the water facilitates the adsorption and polymerization of the organosilane molecules. The anti-stiction coatings formed are usually SAM films.
Some anti-stiction coatings can grow in multiple modes. Some polymerizations resulting in polydimethylsiloxane-like (PDMS-like) polymers are created and are terminated with hydroxyl groups. These hydroxyl groups are detrimental to certain applications such as anti-stiction because they decrease the hydrophobicity of the coating and leave OH groups exposed, which can contribute to stiction. Current anti-stiction films currently in use are perfluorodecyltrichlorosilane (FDTS) and fluoroctatrichlorosilane (FOTS) coatings. However, these thin films contain fluorine, which is undesirable due to environmental concerns.
Therefore, improved techniques are needed to improve anti-stiction coatings.
A method of deposition is provided in a first embodiment. A first layer is deposited on a workpiece. The first layer is formed from a first organosilane precursor and can be an anti-stiction layer. A second organosilane precursor is introduced around the workpiece with the first layer. The second organosilane precursor is different from the first organosilane precursor. The second organosilane precursor is configured to eliminate defect sites and unreacted sites on the first layer and on a surface of the workpiece that includes the first layer.
The first layer can be deposited using vapor deposition.
The method can include depositing the second organosilane precursor on the first layer using vapor deposition.
The first organosilane precursor may be dimethyldichlorosilane or dimethyldiethoxysilane. In an instance, the second organosilane precursor is N,N-dimethyltrimethylsilylamine or trimethylchlorosilane.
The first layer may be a self-assembled monolayer.
The workpiece may be silicon or aluminum oxide.
The defect sites can be hydroxyl groups.
The method can include performing a purging process that uses an inert gas between depositing the first layer and introducing the second organosilane precursor.
The second organosilane precursor may have at least the same chain length as the first organosilane precursor.
A device is provided in a second embodiment. The device includes a workpiece, a first layer disposed on the workpiece, and a second layer disposed on the first layer. The first layer is formed from a first organosilane precursor and can be an anti-stiction layer. The second layer is formed from a second organosilane precursor. The second organosilane precursor is different from the first organosilane precursor. The second organosilane precursor is configured to eliminate defect sites and unreacted sites on the first layer and on a surface of the workpiece that includes the first layer.
The workpiece may be silicon or aluminum oxide.
The first organosilane precursor may be dimethyldichlorosilane or dimethyldiethoxysilane. In an instance, the second organosilane precursor is N,N-dimethyltrimethylsilylamine or trimethylchlorosilane.
The first layer may be a self-assembled monolayer.
The second organosilane precursor may have at least the same chain length as the first organosilane precursor.
The defect sites can be hydroxyl groups.
The workpiece can be part of a MEMS device.
For a fuller understanding of the nature and objects of the disclosure, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:
Although claimed subject matter will be described in terms of certain embodiments, other embodiments, including embodiments that do not provide all of the benefits and features set forth herein, are also within the scope of this disclosure. Various structural, logical, process step, and electronic changes may be made without departing from the scope of the disclosure. Accordingly, the scope of the disclosure is defined only by reference to the appended claims.
Embodiments disclosed herein can improve anti-stiction properties of SAMs or other anti-stiction coatings by eliminating defect sites. A first layer is deposited on a workpiece in the embodiments disclosed herein. The first layer likely contains defect sites, such as hydroxyl groups. A second layer is then deposited, which can eliminate defect sites and on the first layer. The second precursor is then introduced to preferentially react with and remove the defect sites. Thus, the defects in the thin layer formed by the first precursor are repaired. Two different organosilane molecules can be used to form an improved anti-stiction coating.
A first layer 101 is deposited on the workpiece 100 at Step B. The deposition occurs using MVD, another vapor deposition technique, a liquid chemical process, or another deposition technique. A first organosilane precursor 103 is used during the deposition. The first organosilane precursor 103 can be introduced around the workpiece 100 with water. Deposition of the first layer can occur at a temperature from 20° C. to 150° C. In an instance, the first organosilane precursor 103 dosage may be from 0.5 to 2 Torr and the water dosage may be from 0.5 to 4 Torr.
In an example, the first organosilane precursor 103 and water vapor are kept in the MVD chamber from approximately 1-60 minutes. For example, a period of approximately 15 minutes may be used. For better film quality, multiple reaction cycles with the first organosilane precursor 103 may be needed. In an example, from 1-10 reaction cycles are performed.
MVD is a gas-phase reaction between surface reactive chemicals and an appropriately receptive surface, such as that of the workpiece 100. Bi-functional silanes in which one termination of the molecule is reactive can be used. The advantage of a gas phase reaction over a comparable liquid phase process is the control of moisture from the ambient environment, which often results in cross-polymerization of the silane, which leads to particulates on the treated surface. Often a heated sub-atmospheric vacuum chamber is used to allow precise control of the reactants and water content. Additionally the gas phase process allows for treatment of complex parts because the coverage of the reactant is generally diffusion-limited. MEMS sensors can be used to address stiction and other parasitic issues relative to surface-to-surface interactions. An example of a system for MVD is shown in U.S. Publication No. 2013/0312663, which is incorporated by reference in its entirety.
Step C shows the workpiece 100 with the resulting first layer 101 formed from the first organosilane precursor 103. The first layer 101 can be a monolayer or a multilayer. In an instance, the first layer 101 is a self-assembled monolayer. In an instance, the first layer 101 can be an anti-stiction layer. There may be defects on the first layer 101, which can include hydroxyl groups. There may be fewer than 13 defects/nm2 based on the crystal structure of SiO2. Other numbers or frequencies of defects are possible.
While specifically disclosed with respect to hydroxyl groups, other defects can be formed and addressed using the embodiments disclosed herein. For example, the defects can be chlorine, which can be sealed by an amine group such that the reaction byproduct is HCl. Aldehyde can react with amine with H2O as a byproduct. Other OH and NH groups can form defects and can react with the techniques disclosed herein.
The thickness of the resulting first layer 101 can be from approximately 0.2 nm to 10 nm for a silicon workpiece and from approximately 0.2 nm to 100 nm for an aluminum workpiece. In an instance, thickness of the resulting first layer 101 is approximately 1 nm.
A second organosilane precursor 104 is introduced around the workpiece 100 with the first layer 101 in Step D. The second organosilane 104 may be deposited with or without other species. The second organosilane 104 may be the only species necessary to eliminate defect sites. The second organosilane precursor 104 is different from the first organosilane precursor 103. For example, the second organosilane precursor 104 may be deposited onto the workpiece 100 using MVD. Temperature during the deposition of the second organosilane precursor 104 may be from 20° C. to 150° C. Pressure during deposition of the second organosilane precursor 104 may be from 0.1 Torr to 5 Torr.
In an example, the second organosilane precursor 104 is injected into the MVD chamber to be deposited on the first layer 100. The reaction time may be approximately 30 seconds to 2 hours. For example, the reaction time may be approximately 15 minutes. The unreacted second organosilane precursor 104 can be pumped out at the end of Step D.
In Step E, a second layer 102 formed from the second organosilane precursor 104 is formed on the first layer 101. The second organosilane precursor 104 is configured to eliminate defect sites on the first layer 101. The second organosilane precursor 104 is different from the first organosilane precursor 103. The second organosilane precursor 104 repairs the original structure of the first layer 101 by reacting with the hydroxyl groups. The silane functional group in the second organosilane precursor 104 can react with the hydroxyl group in the first layer 101 to form an Si—O bond on the surface of the first layer 101 and release dimethylamine, which can then pumped out of the chamber. This improves the anti-stiction properties of the resulting device because the defect sites are eliminated.
Besides eliminating defect sites on the first layer 101, defect sites on a surface of the workpiece 100 also can be eliminated. This can be the same surface of the workpiece 100 that includes the first layer 101. For example, part of the workpiece 100 may be exposed after the first layer 101 is formed.
The precursor for the first layer 101 is generally small, but this precursor can polymerize to form a longer chain. With a molecule length that is the same as the first organosilane precursor 103 or shorter than the first organosilane precursor 103, the second organosilane precursor 104 can penetrate the first layer 101 to some degree. However, the second organosilane precursor 104 also can be the same length or longer than the first organosilane precursor 103. The length or reactivity of the second organosilane precursor 104 can be selected such that it can react with remaining OH groups, unreacted sites, or defect sites.
While illustrated as a flat layer in
The second layer 102 can be created from a monofunctional precursor. As a monofunctional compound, the second organosilane precursor 104 tends to not introduce any additional defect sites. In contrast, difunctional or trifunctional chemicals can create additional OH groups during the film formation reaction. The monofunctional compounds may scavenge and react with any existing defect sites, which can eliminate them.
Reactivity, dose amount, and size of the second organosilane precursor 104 molecule can be configured to optimize elimination of defects. The functional group may be directly related to the chemical reactivity. Aminosilane functional groups are generally more reactive than chlorosilane and alkoxysilane functional groups. Higher temperature and larger doses also may increase the reactivity due to thermodynamics. A small size of second organosilane precursor 104 molecule means that the molecule can penetrate the voids and vacancies of the first layer 101, which is a geometric effect.
In an instance, the first organosilane precursor 103 is dimethyldichlorosilane (DDMS) or dimethyldiethoxysilane. Other examples of the first organosilane precursor 103 can include other vapor-deposited polymers such as bis(N,N-dimethylamino)dimethylsilane, dimethyldimethoxysilane, diethoxydimethylsilane, or 1,3-Dichloro-1,1,3,3-tetramethyldisiloxane. Mixtures of these precursors also are possible. The first organosilane precursor 103 also can be organosilane monomers that have two reactive functional groups that enable polymerization to form a polymer chain.
In an instance, the second organosilane precursor 104 is N,N-dimethyltrimethylsilylamine (TMSDMA) or trimethylchlorosilane (TMCS). Other organosilanes can be used as the second organosilane precursor 104, such as N,N-diethyltrimethylsilylamine (TMSDEA), methoxytrimethylsilane (TMSOMe), ethoxytrimethylsilane (TMSOEt), trimethylsilyl trifluoromethanesulfonate (TMSOTf), or trimethylsilylfluorosulfonate (TMSOFs). Mixtures of these precursors also are possible. The second organosilane precursor 104 may be selected to avoid certain reaction byproducts, such as HCl or dimethylamine. In an instance, the second organosilane precursor 104 can be a monofunctional silane.
In an instance, the second organosilane precursor 104 may have at least the same chain length as the first organosilane precursor 103.
In an instance, a purging process occurs between introduction of the first organosilane precursor 103 and introduction of the second organosilane precursor 104 or between cycles that introduce the first organosilane precursor 103. The purging process can use an inert gas, such as N2 or Ar. This purges unreacted precursor gases and reaction byproducts.
The resulting device includes the workpiece 100, the first layer 101, and the second layer 102. The first layer 101 can be an anti-stiction layer. The second layer 102 can eliminate defect sites (e.g., hydroxyl groups) on the first layer 101. The first layer 101 and the second layer 102 can be an anti-stiction film.
In an embodiment, the method of
This method is further explained with respect to
An unreacted site is any chemical group that the organosilane precursor can react with. Most unreacted sites for anti-stiction applications are OH groups. For example, unreacted sites may be any remaining OH groups on the surface. This can be an OH group that was originally present on the surface that still exists because it did not react with the first organosilane precursor.
A defect site, such as an OH group, can be formed during the reaction of the first organosilane precursor. A defect site is created later during application of the first layer and is not initially present on the sample surface.
Stiction was measured by atomic force microscope (AFM) in an experiment. An end-capped DDMS coating had dangling hydroxyl groups that need to be passivated. TMSDMA molecules can react with the hydroxyl groups and passivate the DDMS film. A silicon AFM tip was placed in contact with the MVD-coated surfaces to simulate stiction and measure the anti-stiction properties of the coatings.
AFM was carried out in soft tapping mode and force volume mode. 1×1 μm scans were collected with a resolution of 512×512 pixels. 16×16 point adhesion maps over a 50×50 μm area were collected. The TMSDMA end-capped DDMS coating demonstrates less adhesion force than DDMS-only coating, as shown in the table below.
Although the present disclosure has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present disclosure may be made without departing from the scope of the present disclosure. Hence, the present disclosure is deemed limited only by the appended claims and the reasonable interpretation thereof.
