Apparatus and method to achieve continuous interface and ultrathin film during atomic layer deposition

Abstract

A method and apparatus for performing atomic layer deposition in which a surface of a substrate is pretreated to make the surface of the substrate reactive for performing atomic layer deposition.

Description

BACKGROUND OF THE INVENTION

[0003] The present invention relates generally to semiconductor technology and, more particularly, to a method and apparatus for the practice of atomic layer deposition.

[0004] In the manufacture of integrated circuits, many methods are known for depositing and forming various layers on a substrate. Chemical vapor deposition (CVD) and its variant processes are utilized to deposit thin films of uniform and, often times conformal coatings over high-aspect and uneven features present on a wafer. However, as device geometries shrink and component densities increase on a wafer, new processes are needed to deposit ultrathin film layers on a wafer. The standard CVD techniques have difficulty meeting the uniformity and conformity requirements for much thinner films.

[0005] One variant of CVD to deposit thinner layers is a process known as atomic layer deposition (ALD). ALD has its roots originally in atomic layer epitaxy, which is described in U.S. Pat. Nos. 4,058,430 and 4,413,022 and in an article titled “Atomic Layer Epitaxy” by Goodman et al.; J. Appl. Phys. 60(3), Aug. 1, 1986; pp. R65-R80. Generally, ALD is a process wherein conventional CVD processes are divided into single-monolayer depositions, wherein each separate deposition step theoretically reaches saturation at a single molecular or atomic monolayer thickness or less and, then, self-terminates.

[0006] The deposition is an outcome of chemical reactions between reactive molecular precursors and the substrate (either the base substrate or layers formed on the base substrate). The elements comprising the film are delivered as molecular precursors. The desired net reaction is to deposit a pure film and eliminate “extra” atoms (molecules) that comprise the molecular precursors (ligands). In a standard CVD process, the precursors are fed simultaneously into the reactor. In an ALD process, the precursors are introduced into the reactor separately, typically by alternating the flow, so that only one precursor at a time is introduced into the reactor. For example, the first precursor could be a metal precursor containing a metal element M, which is bonded to an atomic or molecular ligand L to form a volatile molecule MLx. The metal precursor reacts with the substrate to deposit a monolayer of the metal M with its passivating ligand. The chamber is purged and, then, followed by an introduction of a second precursor. The second precursor is introduced to restore the surface reactivity towards the metal precursor for depositing the next layer of metal. Thus, ALD allows for single layer growth per cycle, so that much tighter thickness controls can be exercised over standard CVD process. The tighter controls allow for ultrathin films to be grown.

[0007] In practicing CVD, a nucleation step is assumed when a film of stable material is deposited on a stable substrate. Nucleation is an outcome of only partial bonding between the substrate and the film being deposited. Molecular precursors of CVD processes attach to the surface by a direct surface reaction with a reactive site or by CVD reaction between the reactive ingredients on the surface. Of the two, the CVD reaction between the reactive ingredients is more prevalent, since the ingredients have much higher affinity for attachment to each other. Only a small fraction of the initial film growth is due to direct surface reaction.

[0008] An example of nucleation is illustrated in FIGS. 1-3. FIG. 1 shows a substrate 10 having bonding locations 11 on a surface of the substrate. Assuming that the CVD reaction involves a metal (M) and a ligand (Lx) reacting with a non-metal (A) and hydrogen (Hz), the adsorbed species diffuse on the surface and react upon successful MLx-AHz collisions. However, the reaction does not occur at all of the potential attachment (or bonding) locations 11. Generally, defect sites (sites having irregular topology or impurity) are likely to trap molecular precursors for extended times and, therefore, have higher probability to initiate nucleation. In any event, as shown in FIG. 1, the bonding of the precursor to the surface occurs at only some of the bonding locations 12.

[0009] Subsequently, as shown in FIG. 2, the initial bonding sites 12 commence to further grow the thin film material on the surface of the substrate 10. The initial reaction products on the surface are the nucleation seed, since the attached products are immobile and diffusing molecular precursors have a high probability to collide with them and react. The process results in the growing of islands 13 on the substrate surface together with the continuous process of creating new nucleation sites 14. However, as the islands 13 grow larger, the formation of new nucleation seeds is suppressed because most of the collisions occur at the large boundaries of the islands 13.

[0010] As the islands 13 enlarge three-dimensionally, most of the adsorption and reaction processes occur on the island surfaces, especially along the upper surface area of the islands 13. Eventually, this vertical growth results in the islands becoming grains. When the grains finally coalesce into a continuous film, the thickness could be on the order of 50 angstroms. However, as shown in FIG. 3, the separated nucleation sites can result in the formation of grain boundaries and voids 15 along the surface of the substrate, where potential bonding sites failed to effect a bond with the precursor(s). The grain boundaries and voids 15 leave bonding gaps along the surface of the substrate so that substantial film height will need to be reached before a continuous upper surface of the film layer is formed.

[0011] Although the results described above from nucleation is a problem with the standard CVD process, the effect is amplified with ALD. Since ALD utilizes one precursor at a time, the initial bonding will occur due to surface reaction of the initial precursor with sparse surface defects. Accordingly, seed nucleation sites 12 are very sparse (more sparse than CVD) and nucleation proceeds by growing ALD layers on these few seed sites. As a result, the nuclei grow three-dimensional islands 13 and coalesce only at thickness that are comparable to the distance between the nucleation seeds. That is, the voids 15 could be much larger in size, so that a much higher structure is needed to provide a continuos upper surface for the film when only ALD is used.

[0012] Accordingly, if an ALD film can initiate growth on a substrate predominantly by nucleation, the film grows discontinuously for a much thicker distance. Ultimately a much thicker film is practically needed in the case of ALD to achieve continuous film, than that which can be obtained from CVD processes.

[0013] The present invention is directed to providing a technique to deposit ALD thin films of reduced thickness that has continuous interface and film.

SUMMARY OF THE INVENTION

[0014] A method and apparatus for performing atomic layer deposition in which a surface of a substrate is pretreated to make the surface of the substrate reactive for performing atomic layer deposition (ALD). As a result, the ALD process can start continuously without nucleation or incubation, so that continuous interfaces and ultrathin films are formed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a cross-sectional diagram showing a problem encountered with prior art CVD processes, in which sparse seed nuclei are formed to initiate film growth by non-continuous nucleation.

[0016] FIG. 2 is a cross-sectional diagram showing the start of nucleation emanating from the chemical attachment shown in FIG. 1, in which the spacing between the nucleation sites results in the formation of separated islands as the deposition process progresses.

[0017] FIG. 3 is a cross-sectional diagram showing the result of further growth of the deposited layer of FIG. 2, in which the formation of grain boundaries and voids requires more than desirable thickness to be deposited to obtain a continuous layer at the surface.

[0018] FIG. 4 is a cross-sectional diagram showing an embodiment of the present invention in pretreating a surface of a substrate to activate the surface, prior to performing atomic layer deposition to grow an ultra thin film layer.

[0019] FIG. 5 is a cross-sectional diagram showing the presence of many more active sites on the surface of the substrate after surface pretreatment shown in FIG. 4 is performed.

[0020] FIG. 6 is a cross-sectional diagram showing a first sequence for performing ALD when a first precursor is introduced to the prepared surface of FIG. 5.

[0021] FIG. 7 is a cross-sectional diagram showing a formation of ligands on the substrate surface of FIG. 6 after the first precursor reacts with the pretreated surface and the subsequent introduction of a second precursor.

[0022] FIG. 8 is a cross-sectional diagram showing the restoration of the substrate surface of FIG. 7 so that the first precursor can be reintroduced to repeat the ALD cycle for film growth and, in addition, a continuous interface layer of the desired film is deposited on the substrate by the sequences of FIGS. 5-7.

[0023] FIG. 9 is a cross-sectional diagram showing a formation of a next ALD monolayer atop the first monolayer shown in FIG. 8 to further grow the layer above the substrate one atomic/molecular layer at a time.

[0024] FIG. 10 is a cross-sectional diagram showing an alternative pretreatment technique in which an intermediate layer is formed to provide activation sites on the surface of the substrate prior to performing ALD.

[0025] FIG. 11 is a block diagram showing one reactor apparatus for performing ALD, as well as pretreating the surface by practicing the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0026] The practice of atomic layer deposition (ALD) to deposit a film layer onto a substrate, such as a semiconductor wafer, requires separately introducing molecular precursors into a processing reactor. The ALD technique will deposit an ultrathin film layer atop the substrate. The term substrate is used herein to indicate either a base substrate or a material layer formed on a base substrate, such as a silicon substrate. The growth of the ALD layer follows the chemistries associated with chemical vapor deposition (CVD), but the precursors are introduced separately.

[0027] In an example ALD process for practicing the present invention, the first precursor introduced is a metal precursor comprising a metal element M bonded to atomic or molecular ligand L to make a volatile molecule MLx (the x, y and z subscripts are utilized herein to denote integers 1, 2, 3, etc.). It is desirable that the MLx molecule bond with a ligand attached to the surface of the substrate. An example ligand is a hydrogen-containing ligand, such as AH, where A is a nonmetal element bonded to hydrogen. Thus, the desired reaction is noted as AH+MLx→AMLy+HL, where HL is the exchange reaction by-product.

[0028] However, in a typical situation as noted in the Background section above, the substrate surface does not possess ample bonding sites for all the potential locations on the surface. Accordingly, the MLx precursor bonding to the surface can result in the formation of islands and grains which are sufficiently far apart to cause the problems noted above. In order to grow continuous interfaces and films, the present invention is practiced to pretreat the surface of the substrate prior to ALD in order to have the surface more susceptible to ALD. In the preferred embodiment the substrate surface is first treated to make the surface more reactive. This is achieved by forming reactive termination on the surface which will then react with the first ALD precursor.

[0029] FIG. 4 shows one embodiment for practicing the present invention. In FIG. 4, a substrate 20 (again, substrate is used herein to refer to either a base substrate or a material layer formed on a base substrate) is shown upon which ALD is performed. Instead of applying the MLx precursor initially onto the substrate 20, one or more radical specie(s), including such species as oxygen, hydrogen, OH, NH2, Cl and F, is introduced to react with a surface 21 of the substrate 20. The species can be remote plasma generated and carried to the processing chamber. The reactive species can be selected to react with most surfaces, however, the particular specie selected will depend on the surface chemistry. A given specie is utilized to modify the surface 21. The reactive specie typically will modify the surface by exchanging other surface species and/or attaching to previously reconstructed sites.

[0030] For example, SiO2 surface with approximately 100% siloxane SiOSi bridge is generally inert. OH, H or O radical exposure can efficiently insert HOH into the SiOSi to generate 2 Si—OH surface species that are highly reactive with MLx molecular precursor. In FIG. 4, a generic AHz reaction is shown to treat the surface 21 of the substrate 20. A number of example reactions using a particular species to treat various surfaces is described later below.

[0031] The introduction of the pretreatment plasma into the processing chamber containing the substrate 20 results in the formation of surface species at various desired bonding sites. Thus, as shown in FIG. 5, the surface is shown containing AH sites. It is desirable to have the AH species at many of the potential bonding sites. Subsequently, as shown in FIG. 6, the first precursor MLx is introduced to start the ALD process for growing a film layer having the composition MA.

[0032] It should be noted that the prior art practice of performing ALD commences by the introduction of MLx. Since the prior art does not pretreat the surface 21, there is a tendency for the surface to have lot less potential bonding sites. That is, there are lot less AH sites on non-treated surfaces versus the number available for the pretreated surface 21 shown in FIG. 6. Accordingly, with less bonding sites on the surface, the earlier described problems associated with nucleation can occur. However, the pretreated surface 21 allows for many more bonding sites to be present on the surface to reduce the above-noted problem.

[0033] FIGS. 7-9 show the remaining sequence for performing ALD. After the MLx precursor is introduced, the AH+MLx→AMLy+HL reaction occurs, wherein HL is exchanged as the reaction by-product. As shown in FIG. 7, the surface of the substrate 21 now contains the MA-L combination, which then reacts with the second precursor comprising AHz. The second precursor, shown here comprising a nonmetal element A and hydrogen reacts with the L terminated sites on the surface 21. The hydrogen component is typically represented by H2O, NH3 or H2S. The reaction ML+AHz→MAH+HL results in the desired additional element A being deposited as AH terminated sites and the ligand L is eliminated as a volatile by-product HL. The surface 21 now has AH terminated sites, as shown in FIG. 8.

[0034] At this point of the process, the first precursor has been introduced and deposited by ALD, followed by the second precursor, also by ALD. The sequence of surface reactions restores the surface 21 to the initial condition prior to the MLx deposition, thereby completing the ALD deposition cycle. Since each ALD deposition step is self-saturating, each reaction only proceeds until the surface sites are consumed. Therefore, ALD allows films to be layered down in equal metered sequences that are identical in chemical kinematics, deposition per cycle, composition and thickness. Self-saturating surface reactions make ALD insensitive to transport non-uniformity either from flow engineering or surface topography, which is not the case with other CVD techniques. With the other CVD techniques, non-uniform flux can result in different completion time at different areas, resulting in non-uniformity or non-conformity. ALD, due to its monolayer limiting reaction, can provide improved uniformity and/or conformity over other CVD techniques.

[0035] FIG. 9 illustrates the result of a subsequent ALD formation of the MA layer when the next MLx sequence is performed to the surface of the substrate shown in FIG. 8. Thus, additional ALD deposition cycles will further grow the film layer 22 on the surface 21, one atomic or molecular layer at a time, until a desired thickness is reached. With the pretreatment of the surface 21, nucleation problems noted earlier are inhibited, due to ample bonding sites on the surface. Thus, the initial ALD layers, as well as subsequent ALD layers, will have ample bonding sites on the surface to attach the reactive species. Continuous ultrathin film layers of 50 angstroms and under can be deposited with acceptable uniformity and conformity properties when practicing the present invention.

[0036] It is appreciated that the pretreatment of the surface 21 can be achieved to deposit enough radical species to exchange with the surface. In this instance, these radical species (shown as AH in the example illustrated) provide termination sites for bonding to the MLx precursor. However, in some instances, it may be desirable to actually deposit an intermediate layer above the surface 21. In this instance, an actual intermediate layer 23 is formed above the surface 21 and in which the termination sites are actually present on this layer 23. This is illustrated in FIG. 10. Again, this layer can be deposited by a plasma process, including ALD. Then, the ALD process sequence, commencing with the deposition of MLx can commence.

[0037] An intermediate layer may be required in some instances when the substrate cannot be made reactive with either of the ALD molecular precursors by a simple attachment or exchange of surface species. The ultra thin intermediate layer 23 is deposited as part of the pretreatment process. The intermediate layer 23 provides a new surface that is reactive to one or both precursors. The layer 23 is formed having a thickness which is kept minimal, but sufficient for activation. The intermediate layer 23 may be conductive, semiconductive or insulating (dielectric). Typically, it will match the electrical properties of either the substrate 20 or the overlying film being grown. For example, layer 23 is needed as a transition layer when W or WNx films are deposited on SiO2. In this instance, Al2O3 (which is an insulator) or TiN, Ti, Ta or TaxN (which are conductors) can be used for the intermediate layer 23.

[0038] It is to be noted further, that the intermediate layer 23 can be deposited by ALD for the pretreatment of the surface. Additionally, the surface 21 of the substrate 20 can be pretreated first by the first method described above to prepare the surface 21 for the deposition of the intermediate layer 23. Although this does require additional process, it may be desirable in some instances.

[0039] It is appreciated that the pretreatment of surface 21 is achieved by a plasma process in the above description, including the use of ALD. However, other techniques can be used instead of a plasma process to pretreat the surface 21. Thus, the surface 21 can be treated, even the intermediate layer 23 grown, by other techniques. Furthermore, a leaching process can be utilized. Since some surfaces are quite inert, a process other than reactive exchange or attachment may be desirable. For example, hydrocarbon and fluorocarbon polymers are utilized for low-k dielectrics. Adhesion of films, for sealing (insulating) or for forming a barrier (metals, metal nitrides), is difficult to achieve. In these instances, leaching hydrogen or fluorine from the top layer of the polymer can activate the surface for ALD.

[0040] Thus, a number of techniques are available for pretreating a surface of a substrate so that the surface is more active for ALD. The present invention can be implemented in practice by a number of chemistries and chemical reactions. A number of examples are provided below with relevant equations. It is to be understood that the examples listed below are provided as examples and in no way limit the invention to just these examples.

EXAMPLE 1

ALD Deposition of Al2O3 on Silicon

[0041] A silicon substrate is first activated (pretreated) by forming thin layers of silicon oxide (SiO2) or silicon oxinitride, in which OH and/or NHx groups form the terminations. The process involves O2/H2/H2O/NH3 remote plasma that includes different ratios of the constituents to form the terminations prior to the introduction of the first precursor to grow the Al2O3 thin film layer on silicon.

Si—H+OH.+H.+NHx.→Si—OH+Si—NHx

[0042] (where “.” defines a radical)

Si—OH+Al(CH3)3→Si—O—Al(CH3)2+CH4

Si—NHx+Al(CH3)3→Si—NHx−1—Al(CH3)2+CH4

EXAMPLE 2

ALD Deposition of Al2O3 on Silicon

[0043] The silicon substrate is activated by forming thin layers of SiO2 that is hydroxilated by exposing HF cleaned (H terminated) silicon to a pulse of H2O at temperatures below 430° C. This process results in a self-saturated layer of SiO2 that is approximately 5 angstroms thick.

Si—H+H2O→Si—O—Si—OH+H2

Si—OH+Al(CH3)3→Si—O—Al(CH3)2+CH4

EXAMPLE 3

ALD Deposition of Al2O3 on WNx

[0044] NH3/H2/N2 plasma is used to leach fluorine from the top layers of the WNx film and terminate the surface with NHx species. These species are reacted with trimethyl aluminum (TMA) to initiate deposition of Al2O3 on WNx.

WxN+H.+NHx→W—NHx

W—NHx+Al(CH3)3→W—NHx−1—Al(CH3)2+CH4

EXAMPLE 4

ALD Deposition of Al2O3 on TiN

[0045] NH3/H2/N2 plasma is used to terminate the surface with NHx species. These species are reacted with TMA to initiate Al2O3 ALD.

TiN+He.+NHx.→Ti—NHx

TiNHx+Al(CH3)3TiNHx−1—Al(CH3)2+CH4

EXAMPLE 5

ALD Deposition of Al2O3 on Ti

[0046] NH3/H2/N2 plasma is used to nitridize the surface and terminate the surface with NHx species. Maintain conditions to avoid extensive nitridization into the Ti film. The NHx species are reacted with TMA to initiate Al2O3 ALD.

Ti+NHx.+H.→TiNHx

TiNHx+Al(CH3)3→TiNHx−1—Al(CH3)2+CH4

[0047] EXAMPLE 6

ALD Deposition of Al2O3 on W

[0048] NH3/H2/N2 plasma is used to nitridize the surface and terminate the surface with NHx species. Maintain conditions to avoid extensive nitridization into the W film. The NHx species are reacted with TMA to initiate Al2O3 ALD.

W+NHx.+H.→WNHx

W—NHx+Al(CH3)3→W—NHx−1—Al(CH3)2+CH4

EXAMPLE 7

ALD Deposition of Al2O3 on Ta

[0049] NH3/H2/N2 plasma is used to nitridize the surface and terminate the surface with NHx species. Maintain conditions to avoid extensive nitridization into the Ta film. The NHx species are reacted with TMA to initiate Al2O3 ALD.

Ta+NHx.+H.→TaNHx

TaNHx+Al(CH3)3→TaNHx−1—Al(CH3)2+CH4

EXAMPLE 8

ALD Deposition of Al2O3 on TaxN

[0050] NH3/H2/N2 plasma is used to terminate the surface with NHx species. The NHx species are reacted with TMA to initiate Al2O3 ALD.

TaxN+NHx.+H.→TaNHx

TaNHx+Al(CH3)3→TaNHx−1—Al(CH3)230 CH4

EXAMPLE 9

ALD Deposition of Ta2O5 on Al2O3

[0051] The process involves O2/H2/H2O remote plasma that includes different ratios of the constituents. This plasma is used to terminate the surface with OH species that are reactive with TaCl5.

Al2O3+OH.+O.+H.→Al2O3—OH

Al2O3—OH+TaCl5→Al2O3—O—TaCl4+HCl

EQUATION 10

ALD Deposition of Al2O3 on Ta2O5

[0052] The process involves O2/H2/H2O remote plasma that includes different ratios of the constituents. This plasma is used to terminate the surface with OH species that are reactive with TaCl5.

Ta2O5+O.+H.+OH.→Ta2O5—OH

Ta2O5—OH+Al(CH3)3→Ta2O5—O—Al(CH3)2+CH4

EXAMPLE 11

ALD Deposition of TiOx on Al2O3

[0053] The process involves O2/H2/H2O remote plasma that includes different ratios of the constituents. This plasma is used to terminate the surface with OH species that are reactive with TMA.

Al2O3+O.+H.+OH.→Al2O3—OH

Al2O3—OH+TiCl4→Al2O3—O—TiCl3+HCl

EXAMPLE 12

ALD Deposition of Al2O3 on TiOx

[0054] The process involves O2/H2/H2O remote plasma that includes different ratios of the constituents. This plasma is used to terminate the surface with OH species that are reactive with TiCl4.

TiO2+O.+H.+OH.→TiO2—OH

TiO2—OH+Al(CH3)3→TiO2—O—Al(CH3)2+CH4

EXAMPLE 13

ALD Deposition of TiOx on TiN

[0055] NH3/H2/N2 plasma is used to terminate the surface with NHx species. The NHx species are reacted with TiCl4 to initiate TiOx ALD.

TiN+H.+NHx.→Ti—NHx

Ti—NHx+TiCl4→TiNHx−1TiCL3+HCl

EXAMPLE 14

ALD Deposition of W on TiN

[0056] NH3/H2/N2 plasma is used to terminate the surface with NHx species. The NHx species are reacted with TiCl4 to initiate TiN ALD.

TiN+H.+NHx.→Ti—NHx

Ti—NHx+WF6→TiNHx−1—WF5+HF

EXAMPLE 15

ALD Deposition of WNx on TiN

[0057] NH3/H2/N2 plasma is used to terminate the surface with NHx species. The NHx species are reacted with TiCl4 to initiate WNx ALD.

TiN+H.+NHx.→Ti—NHx

Ti—NHx+WF6→TiNHx−1—WF5+HF

EXAMPLE 16

[0058] ALD Deposition of WNx on SiO2

[0059] O2/H2/H2O remote plasma that includes different ratios of the constituents is used to terminate the surface with OH species that are reactive with TiCl4. The TiCl4 species is used to grow an intermediate layer of Ti or TiN. The final layer is terminated with NHx species (from the TiN ALD) which reacts with WF6 to initiate the WNx ALD process.

SiO2+H.+O.+OH.→Si—OH

Si—OH+TiCl4→SiO—TiCl3+HCl

SiO—TiCl3+NH3→SiO—TiN—NHx+HCl

SiO—TiN—NHx+WF6→SiO—TiN—NHx−1WF5+HF

EXAMPLE 17

ALD Deposition of W on SiO2

[0060] O2/H2/H2O remote plasma that includes different ratios of the constituents is used to terminate the surface with OH species that are reactive with TiCl4. The TiCl4 species is used to grow an intermediate layer of Ti or TiN. The final layer is terminated with NHx species (from the TiN ALD) which reacts with WF6 to initiate the W ALD process.

SiO2+H.+O.+OH.→Si—OH

Si—OH+TiCl4→SiO—TiCl3+HCl

SiO—TiCl3+NH3→SiO—TiN—NHx+HCl

SiO—TiN—NHx+WF6→SiO—TiN—NHx−1WF5 +HF

[0061] Alternatively, TaCl5 can be used for growing an intermediate TaxN layer.

EXAMPLE 18

ALD Deposition of WNx on Hydrocarbon Polymer (Low-k Dielectric Layer)

[0062] NF3 remote plasma generates fluorine atoms that leach out hydrogen from the hydrocarbon. The leached surface is reacted with TiCl4 and followed by TiN or Ti/TiN ALD of a thin intermediate layer. The NHx terminated surface that is prepared during the TiN ALD is reacted with WF6 to initiate WNx ALD.

CnHm+F.→CpHqC.

CpHqC.+TiCl4→CpHq−1CTiCl3+HCl

CpHq−1CTiCl3+NH3→CpHq−1CtiN—NHx+HC

CpHq−1CtiN—NHx+WF6→CpHq−1CTiNx−1—WF5+HF

EXAMPLE 19

ALD Deposition of WNx on Perfluorocarbon Polymer (Low-k Dielectric Layer)

[0063] H2/NH3 remote plasma generates H atoms and NHx radicals that leach out fluorine from the hydrocarbon. The leached surface is reacted with TiCl4 and followed by TiN or Ti/TiN ALD of a thin intermediate layer. The NHx terminated surface that is prepared during the TiN ALD is reacted with WF6 to initiate WNx ALD.

CmFn+H.+NHx.→CpFqC.+HF

CpFqC.+TiCl4→CpFqC—TiN—NHx

CpFqC—TiN—NHx+WF6→CpFqC—TiNHx−1—NWF5+HF

EXAMPLE 20

ALD Deposition of Oxide on Another Oxide

[0064] The surface of the first oxide is activated by O2/H2/H2O remote plasma that includes different ratios of the constituents. This process is used to terminate the surface with OH species that are reactive with a metal precursor for the next oxide layer.

M1Ox+O.+H.+OH.→M1Ox—OH

M1Ox—OH+M2Ly→M1Ox—O—M2Ly−1+HL

EXAMPLE 21

ALD Deposition of Oxide on Metal, Semiconductor or Metal Nitride

[0065] NH3/H2/N2 plasma is used to terminate the surface with NHx species that are reactive with a metal precursor for initiating ALD.

M1+H.+NHx.→M1—NHx

M1NHx+M2Ly→M1NHx−1M2Ly−1+HL

EXAMPLE 22

ALD Deposition of Metal, Semiconductor or Conductive Metalnitride on Oxide

[0066] NH3/H2/N2 plasma is used to terminate the surface with NHx species or O2/H2/H2O plasma generated radicals are used to terminate the surface with OH species. The species are reactive with a metal precursor for initiating ALD.

M1Ox+O.+H.+OH.→M1Ox—OH

M1Ox—OH+M2Ly→M1Ox—O—M2Ly−1+HL

[0067] Again, it is appreciated that the above are described as examples only and that many other ALD reactions and pretreatment procedures are available.

[0068] Referring to FIG. 11, an apparatus for practicing the present invention is shown. An ALD reactor apparatus 30 is shown as one embodiment. It is appreciated that a variety of other devices and equipment can be utilized to practice the invention. Reactor 30 includes a processing chamber 31 for housing a wafer 32. The wafer 32 comprises the substrate 20 described in the earlier Figures. Typically, the wafer 32 resides atop a support (or chuck) 33. A heater 34 is also coupled to the chuck to heat the chuck 33 and the wafer 32 for plasma deposition. The processing gases are introduced into the chamber 31 through a gas distributor 35 located at one end of the chamber 31. A vacuum pump 36 and a throttling valve 37 are located at the opposite end to draw and regulate the gas flow across the wafer surface.

[0069] A mixing manifold 38 is used to mix the various processing gases and the mixed gases are directed to a plasma forming zone 39 for forming the plasma. A variety of CVD techniques for combining gases and forming plasma can be utilized, including adapting techniques known in the art. The remotely formed plasma is then fed into gas distributor 35 and then into the chamber 31.

[0070] The mixing manifold 38 has two inlets for the introduction of gases and chemicals. A carrier gas is introduced and the flow split at the mixing manifold 38. The carrier gas is typically an inert gas, such as nitrogen. The mixing manifold 38 also has two inlets for the chemicals. In the example diagram of FIG. 11, chemical A and chemical B are shown combined with the carrier gas. Chemistry A pertains to the first precursor and chemistry B pertains to the second precursor for performing ALD for the two precursor process described above. Chemical selection manifold 40 and 41, comprised of a number of regulated valves, provide for the selecting of chemicals that can be used as precursors A and B, respectively. Inlet valves 42 and 43 respectively regulate the introduction of the precursor chemistries A and B into the mixing manifold 38.

[0071] The operation of the reactor for performing ALD is as follows. Once the wafer is resident within the processing chamber 31, the chamber environment is brought up to meet desired parameters. For example, raising the temperature of the wafer in order to perform ALD. The flow of carrier gas is turned on so that there is a constant regulated flow of the carrier gas as the gas is drawn by the vacuum created by the pump 36. When ALD is to be performed, valve 42 is opened to allow the first precursor to be introduced into the carrier gas flow. After a preselected time, valve 42 is closed and the carrier gas purges any remaining reactive species. Then, valve 43 is opened to introduce the second precursor into the carrier gas flow. Again after another preselected time, the valve 43 is closed and the carrier gas purges the reactive species form the chambers of the reactor. The two chemicals A and B are alternately introduced into the carrier flow stream to perform the ALD cycle to deposit a film layer.

[0072] When the pretreatment of the surface is to be performed by plasma, the pretreating species can be introduced into the mixing manifold through either or both of the chemical selection routes through selection manifold(s) 40, 41 to mix with the carrier gas. Again, the pretreatment is performed prior to the initial introduction of the first ALD precursor used to deposit the film. Accordingly, the introduction of the pretreatment chemistry can be achieved from adapting designs of a standard ALD reactor.

[0073] Thus, an apparatus and method to achieve continuous interface and ultrathin film during atomic layer deposition is described. The present invention allows an ALD process to start continuously without nucleation or incubation and allows ultrathin film layers of 50 angstroms or less in thickness to be deposited having continuous uniformity and/or conformity.

Claims

1. A method of performing atomic layer deposition comprising: pretreating a surface of a substrate to make the surface of the substrate reactive for performing atomic layer deposition; introducing a first precursor to deposit a first reactive species on the surface of the substrate, the pretreated surface being more receptive to having chemical termination sites for depositing the first reactive species, due to said pretreating the surface; and introducing a second precursor to have a second reactive species react with the deposited first reactive species.

2. The method of claim 1 further including forming a uniform film layer of 50 angstroms or less in thickness.

3. The method of claim 1 wherein said pretreating is performed by a plasma process.

4. The method of claim 1 wherein said pretreating the surface includes introducing a radical species to attach to the surface of the substrate to increase termination sites for the first reactive species.

5. The method of claim 4 wherein said pretreating is performed by a plasma process.

6. The method of claim 1 wherein said pretreating the surface includes introducing a radical species to exchange bonds at the surface of the substrate to increase termination sites for the first reactive species.

7. The method of claim 6 wherein said pretreating is performed by a plasma process.

8. The method of claim 1 wherein said pretreating the surface includes depositing an intermediate layer on the substrate prior to introducing the first precursor, in which the intermediate layer provides more termination sites for the first reactive species than the substrate or where the substrate cannot be made reactive to atomic layer deposition.

9. The method of claim 8 wherein said pretreating is performed by a plasma process.

10. The method of claim 8 wherein said pretreating is performed by an atomic layer deposition plasma process.

11. The method of claim 1 wherein said pretreating the surface includes introducing a radical species to leach molecules from the substrate to increase termination sites for the first reactive species.

12. The method of claim 11 wherein said pretreating is performed by a plasma process.

13. The method of claim 1 wherein Al2O3 is deposited on silicon by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O/NH3 plasma to form a layer of silicon oxide or silicon oxinitride, in which OH or NHx group forms the chemical termination sites on silicon.

14. The method of claim 1 wherein Al2O3 is deposited on silicon by atomic layer deposition in which said pretreating includes forming a layer of SiO2 that is hydroxilated by exposing HF cleaned silicon to a pulse of H2O to form the chemical termination sites on silicon.

15. The method of claim 1 wherein Al2O3 is deposited on WNx by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to leach fluorine from WNx to form NHx as the chemical termination sites on WNx.

16. The method of claim 1 wherein Al2O3 is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx as the chemical termination sites on TiN.

17. The method of claim 1 wherein Al2O3 is deposited on Ti by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to nitridize the surface to form NHx as the chemical termination sites on Ti.

18. The method of claim 1 wherein Al2O3 is deposited on W by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to nitridize the surface to form NHx as the chemical termination sites on W.

19. The method of claim 1 wherein Al2O3 is deposited on Ta by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to nitridize the surface to form NHx as the chemical termination sites on Ta.

20. The method of claim 1 wherein Al2O3 is deposited on TaxN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx as the chemical termination sites on TaxN.

21. The method of claim 1 wherein Ta2O5 is deposited on Al2O3 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH species as the chemical termination sites on Al2O3.

22. The method of claim 1 wherein Al2O3 is deposited on Ta2O5 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH species as the chemical termination sites on Ta2O5.

23. The method of claim 1 wherein TiOx is deposited on Al2O3 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH species as the chemical termination sites on Al2O3

24. The method of claim 1 wherein Al2O3 is deposited on TiOx by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH species as the chemical termination sites on TiOx.

25. The method of claim 1 wherein TiOx is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx species as the chemical termination sites on TiN.

26. The method of claim 1 wherein W is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx species as the chemical termination sites on TiN.

27. The method of claim 1 wherein WNx is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx species as the chemical termination sites on TiN.

28. The method of claim 1 wherein WNx is deposited on SiO2 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH species that are reactive with TiCl4 and in which the TiCl4 is used to grow an intermediate layer of Ti or TiN to form NHx as the chemical termination sites on Ti or TiN.

29. The method of claim 1 wherein W is deposited on SiO2 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH species that are reactive with TiCl4 and in which the TiCl4 is used to grow an intermediate layer of Ti or TiN to form NHx as the chemical termination sites on Ti or TiN.

30. The method of claim 1 wherein W is deposited on SiO2 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH species that are reactive with TaCl5 and in which the TaCl5 is used to grow an intermediate layer of TaxN to form NHx as the chemical termination sites on TaxN.

31. The method of claim 1 wherein WNx is deposited on hydrocarbon polymer by atomic layer deposition in which said pretreating includes introducing NF3 plasma to generate fluorine atoms that leach hydrogen from the hydrocarbon polymer and in which the leached surface is reacted with TiCl4 to grow an intermediate layer of TiN or a combination of Ti/TiN to form NHx as the chemical termination sites on TiN or Ti/TiN.

32. The method of claim 1 wherein WNx is deposited on perfluorocarbon polymer by atomic layer deposition in which said pretreating includes introducing H2/NH3 plasma to generate hydrogen atoms and NHx radicals that leach fluorine from the hydrocarbon polymer and in which the leached surface is reacted with TiCl4 to grow an intermediate layer of TiN or a combination of Ti/TiN to form NHx as the chemical termination sites on TiN or Ti/TiN.

33. The method of claim 1 wherein a second oxide is deposited on a first oxide by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to activate the first oxide and to terminate the surface with OH species that are reactive with a metal precursor for the second oxide layer.

34. The method of claim 1 wherein an oxide is deposited on metal, semiconductor or metal nitride by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to terminate the surface with NHx species that are reactive with a metal precursor.

35. The method of claim 1 wherein a metal, semiconductor or conductive metalnitride is deposited on oxide by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma which is used to terminate the surface with NHx species.

36. The method of claim 1 wherein a metal, semiconductor or conductive metalnitride is deposited on oxide by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma generated radicals which are used to terminate the surface with OH species.

37. An apparatus for performing atomic layer deposition comprising: a processing chamber for subjecting a substrate to atomic layer deposition to deposit a film layer; a mixing manifold for mixing chemicals with a carrier gas, said mixing manifold coupled to said processing chamber for delivery of a first precursor chemical during a first time period and delivery of a second precursor chemical during a second period to generate a first and second plasma, respectively, to perform atomic layer deposition to deposit the film layer; said mixing manifold also coupled to receive a pretreating chemical specie for coupling into said processing chamber prior to introduction of the first and second precursor chemicals, said pretreating chemical specie introduced into said processing chamber to pretreat the substrate surface to make its surface more reactive to the first precursor chemical.

38. The apparatus of claim 37 wherein said pretreating chemical specie introduces a radical species to attach to the surface of the substrate to increase termination sites for the first precursor chemical.

39. The apparatus of claim 37 wherein said pretreating chemical specie introduces a radical species to exchange bonds at the surface of the substrate to increase termination sites for the first precursor chemical.

40. The apparatus of claim 37 wherein said pretreating chemical specie deposits an intermediate layer on the substrate prior to introducing the first precursor chemical, in which the intermediate layer provides more termination sites for the first precursor chemical or where the substrate cannot be made reactive to atomic layer deposition.

41. The apparatus of claim 37 wherein said pretreating chemical specie introduces a radical species to leach molecules from the substrate to increase termination sites for the first precursor chemical.

42. A method to perform atomic layer deposition comprising: pretreating a surface of a substrate or a material layer formed on the substrate by introducing a radical specie including any combination of O2, H2, H2O, NH3, NF3, N2, Cl and F to increase AHx termination sites on the surface, where x is an integer and A is a non-metal capable of bonding with hydrogen H; introducing a first precursor to deposit a first reactive specie on the surface, the surface when pretreated being more receptive to have additional bonding with the first reactive specie, due to the increase of AHx termination sites on the surface; and introducing a second precursor, after the bonding of the first reactive specie, to deposit a second reactive specie to react with the deposited first reactive specie to form a film layer.

43. The method of claim 42 further including forming the film layer to have a thickness of 50 angstroms or less by repeatedly introducing the first precursor followed by the second precursor.

44. The method of claim 42 wherein said pretreating the surface includes introducing the radical specie to exchange bonds at the surface of the substrate to increase AHx termination sites for the first reactive specie.

45. The method of claim 42 wherein said pretreating the surface forms NHx termination sites.

46. The method of claim 42 further comprising forming an intermediate layer on the substrate prior to introducing the first precursor, wherein the radical specie is introduced with the intermediate layer to increase termination sites for the first reactive specie.

47. The method of claim 42 wherein said pretreating the surface includes introducing the radical specie to leach molecules from the substrate to increase termination sites for the first reactive specie.

48. The method of claim 42 wherein said pretreating further includes introducing the radical specie by plasma.

49. The method of claim 42 wherein said pretreating further includes introducing the radical specie by plasma and the reactive species form the film layer, wherein the film layer is comprised of a metal, metal oxide or metal nitride.

50. The method of claim 48 wherein Al2O3 is deposited on silicon by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O/NH3 plasma to form a film layer of silicon oxide or silicon oxinitride, in which OH or NHx group forms the termination sites on silicon.

51. The method of claim 48 wherein Al2O3 is deposited on WNy, where y is an integer, by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to leach fluorine from WNy to form NHx as the termination sites on WNy.

52. The method of claim 48 wherein Al2O3 is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx as the termination sites on TiN.

53. The method of claim 48 wherein Al2O3 is deposited on Ti by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to nitridize the surface to form NHx as the termination sites on Ti.

54. The method of claim 48 wherein Al2O3 is deposited on W by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to nitridize the surface to form NHx as the termination sites on W.

55. The method of claim 48 wherein Al2O3 is deposited on Ta by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to nitridize the surface to form NHx as the termination sites on Ta.

56. The method of claim 48 wherein Al2O3 is deposited on TayN, where y is an integer, by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx as the termination sites on TayN.

57. The method of claim 48 wherein Ta2O5 is deposited on Al2O3 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH specie as the termination sites on Al2O3.

58. The method of claim 48 wherein Al2O3 is deposited on Ta2O5 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH specie as the termination sites on Ta2O5.

59. The method of claim 48 wherein TiOz, where z is an integer, is deposited on Al2O3 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH specie as the termination sites on Al2O3

60. The method of claim 48 wherein Al2O3 is deposited on TiOz, where z is an integer, by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH specie as the termination sites on TiOz.

61. The method of claim 48 wherein TiOz, where z is an integer, is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx specie as the termination sites on TiN.

62. The method of claim 48 wherein W is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx specie as the termination sites on TiN.

63. The method of claim 48 wherein WNy, where y is an integer, is deposited on TiN by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to form NHx specie as the termination sites on TiN.

64. The method of claim 48 wherein WNy, where y is an integer, is deposited on SiO2 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH specie that are reactive with TiCl4 and in which the TiCl4 is used to grow an intermediate layer of Ti or TiN to form NH, as the termination sites on Ti or TiN.

65. The method of claim 48 wherein W is deposited on SiO2 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH specie that are reactive with TiCl4 and in which the TiCl4 is used to grow an intermediate layer of Ti or TiN to form NHx as the termination sites on Ti or TiN.

66. The method of claim 48 wherein W is deposited on SiO2 by atomic layer deposition in which said pretreating includes introducing O2/H2/H2O plasma to form OH specie that is reactive with TaCl5 and in which the TaCl5 is used to grow an intermediate layer of TazN, where z is an integer, to form NHx as the termination sites on TazN.

67. The method of claim 48 wherein WNy, where y is an integer, is deposited on hydrocarbon polymer by atomic layer deposition in which said pretreating includes introducing NF3 plasma to generate fluorine atoms that leach hydrogen from the hydrocarbon polymer and in which the leached surface is reacted with TiCl4 to grow an intermediate layer of TiN or a combination of Ti/TiN to form NHx as the termination sites on TiN or Ti/TiN.

68. The method of claim 48 wherein WNy, where y is an integer, is deposited on perfluorocarbon polymer by atomic layer deposition in which said pretreating includes introducing H2/NH3 plasma to generate hydrogen atoms and NHx radicals that leach fluorine from the hydrocarbon polymer and in which the leached surface is reacted with TiCl4 to grow an intermediate layer of TiN or a combination of Ti/TiN to form NHx as the termination sites on TiN or Ti/TiN.

69. The method of claim 48 wherein an oxide is deposited on metal, semiconductor or metal nitride by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma to terminate the surface with NHx specie that are reactive with a metal precursor.

70. The method of claim 48 wherein a metal, semiconductor or conductive metal nitride is deposited as the film layer on oxide by atomic layer deposition in which said pretreating includes introducing NH3/H2/N2 plasma which is used to terminate the surface with NHx specie.

71. A method to perform atomic layer deposition comprising: depositing an intermediate layer; pretreating a surface of the deposited intermediate layer by introducing a radical specie including any combination of O2, H2, H2O, NH3, NF3, N2, Cl and F to increase AHx termination sites on the surface, where x is an integer and A is a non-metal capable of bonding with hydrogen H; introducing a first precursor to deposit a first reactive specie on the surface, the surface when pretreated being more receptive to have additional bonding with the first reactive specie, due to the increase of AHx termination sites on the surface; and introducing a second precursor, after the bonding of the first reactive specie, to deposit a second reactive specie to react with the deposited first reactive specie to form a film layer.

72. A method to perform atomic layer deposition comprising: leaching hydrogen or fluorine from a surface by pretreating the surface by introducing a radical specie including any combination of O2, H2, H2O, NH3, NF3, N2, Cl and F to increase AHx termination sites on the surface, where x is an integer and A is a non-metal capable of bonding with hydrogen H; introducing a first precursor to deposit a first reactive specie on the surface, the surface when pretreated being more receptive to have additional bonding with the first reactive specie, due to the increase of AHx termination sites on the surface; and introducing a second precursor, after the bonding of the first reactive specie, to deposit a second reactive specie to react with the deposited first reactive specie to form a film layer.

73. A structure formed on a substrate comprising: a material layer formed on the substrate in which the material layer is pretreated by introducing a radical specie including any combination of O2, H2, H2O, NH3, NF3, N2, Cl and F to increase AHx termination sites on the surface of the material layer, where x is an integer and A is a non-metal capable of bonding with hydrogen H; a film layer formed above said material layer by repeated introduction of a first precursor followed by a second precursor to deposit said film layer by atomic layer deposition, the first precursor to deposit a first reactive specie on the surface of the material layer, the surface when pretreated being more receptive to have additional bonding with the first reactive specie, due to the increase of AHx termination sites on the surface and the second precursor to deposit a second reactive specie to react with the deposited first reactive specie to form said film layer.