The information disclosed herein relates generally to semiconductors, including semiconductor memory.
The semiconductor device industry has a market driven need to reduce the size of devices used in products such as processor chips, mobile telephones and memory, such as flash memory. Currently, the semiconductor industry relies on the ability to reduce or scale the dimensions of its basic devices. This can include scaling dielectric regions, which are often formed of silicon dioxide (SiO2). However, increased scaling and other requirements in microelectronic devices have made SiO2 less useful because of its band gap and dielectric properties. Thus, there is a general need for new dielectric structures as device dimensions shrink.
The following description and the drawings sufficiently illustrate specific embodiments of the invention to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Examples merely typify possible variations. Portions and features of some embodiments may be included in, or substituted for, those of other embodiments. Embodiments of the invention set forth in the claims encompass all available equivalents of those claims. Embodiments of the invention may be referred to herein, individually or collectively, by the term “invention” merely for convenience and without intending to limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed.
In the following description, the “substrate” refers generally to any structure on which integrated circuits are formed and also to such structures during various stages of integrated circuit fabrication. The term substrate is understood to include a semiconductor wafer and may include other layers that have been fabricated thereupon. Both wafer and substrate include doped and undoped semiconductors, epitaxial semiconductor layers supported by a base semiconductor or insulator, as well as other semiconductor structures well known to one skilled in the art. The term conductor is understood to generally include n-type and p-type semiconductors and the term insulator or dielectric is defined to include any material that is less electrically conductive than the materials referred to as conductors. The term “high-κ” refers, generally, to a dielectric constant that is substantially greater than 3.9.
Reducing the device dimensions, including its dielectric portions, is desirable for achieving a high density of electronic devices on a wafer. However, reducing dimensions can produce higher device leakage currents and lower device breakdown voltages. A dielectric's dimensions can become increasingly relevant less than 50 nm, particularly for a floating-gate based flash memory device. A way to reduce the thickness of a dielectric region without a proportionate increase in the leakage current or reduction in dielectric breakdown voltage is to use an material with a high dielectric constant.
A useful metric for characterizing a dielectric using its actual physical thickness (ta) is equivalent oxide thickness (teq). teq can be considered the thickness of a theoretical SiO2 layer that achieves the same capacitance density of a specified dielectric. For a specified capacitance, ta of a dielectric material can be related to its teq by
t
eq=(κox/κ)ta=(3.9/κ)ta,
where κ is the dielectric constant of the specified dielectric and κox=3.9 is the dielectric constant for SiO2. Thus, materials with a dielectric constant greater than SiO2 can provide a teq that is smaller than ta. For example, Si3N4 with a dielectric constant of about 7.5 and a thickness of about 20 nm can be used in place of SiO2. The resulting teq is about 10.4 nm, excluding depletion/inversion layer effects. Typical values for teq range from about 5 nm to about 13 nm, but can be more or less, depending on the dielectric constant. Therefore, materials with a dielectric constant larger than SiO2 allow the dielectric to be thinner without a commensurate loss in capacitance, which in turn assists in the scaling of semiconductor devices.
Another useful metric for characterizing a dielectric is degree of capacitive voltage coupling between conductive gates expressed as the gate coupling ratio (GCR). The GCR can be represented as,
GCR=C
ig
/C
T,
where Cig is the capacitance of the dielectric material between the conductive gates and CT is the total capacitance of the structure. Since Cig is proportional to the dielectric constant of a material (κig), a dielectric constant that is greater than SiO2 can increase the GCR beyond that of SiO2. Thus, use of materials with ever larger dielectric constants can enable a reduction in gate leakage current without a corresponding reduction in gate voltage in a device, such as a flash memory device. Materials with a dielectric constant larger than that of SiO2 are called as high-κ dielectrics materials. Examples of high-κ dielectrics include, but are not limited to, the oxides of aluminum (Al), hafnium (Hf), zirconium (Zr), lanthanum (La), tantalum (Ta), tungsten (W), titanium (Ti), dysprosium (Dy), yttrium (Y) and scandium (Sc), the nitrides of Al, Si and boron (B), the oxynitrides SiOxNy and HfOxNy, the mixed oxides HfAlOx, TiAlOx and ZrAlOx, the silicates HfSiOx, ZrSiOx and TaSiOx, and the perovskites SrTiOx and LaTiOx. Dielectric constant values for high-κ dielectrics materials range from about 7 to about 100, depending on the dielectric.
Despite the possible enhancement in voltage coupling between gates, process integration issues may limit use of many high-κ dielectric materials with silicon, particularly with the high-κ dielectrics that contain oxygen or are oxide-based. During formation of an oxide-based high-κ dielectric on polysilicon, some SiO2 may form due to a reaction between oxygen and silicon. The resulting structure is a parasitic layer of SiO2 separating the polysilicon gate from the high-K dielectric layer. A composite dielectric may also form that includes oxygen that is reactive with silicon. This can happen, for example, during the deposition and processing of a nitride such as silicon nitride, where the unintentional incorporation of oxygen can produce a silicon oxynitride mixture having a ratio of Si/N that is other than 3/4. If, as with the case of a floating gate structure, such as a nonvolatile memory device, a second polysilicon gate is formed on the oxide-based high-κ dielectric layer, then a second parasitic layer of SiO2 separating the second polysilicon gate from the high-κ dielectric layer may form. The resulting dielectric composite consists of stacked parasitic SiO2 and high-κ dielectric layers that can have a lower dielectric strength and lower effective dielectric constant than that of the high-κ dielectric alone. In such a case, the capacitance can be modeled as three dielectrics in series, where the teq of the dielectric stack is the sum of the thicknesses of the two parasitic SiO2 layers and a multiplicative factor of the ta of the high-κ inter-gate dielectric being formed. Considering only SiO2 (i.e., no mixtures with SiO2) then,
t
eq
=t
acSiO2
+t
afSiO2+(3.9/κ)ta,
where tacSiO2 and tafSiO2 are the actual thicknesses of the SiO2 layers formed, for example, at the control and floating gate, respectively. A high-κ dielectric material with a dielectric constant of 10 and a thickness of about 20 nm, in series with 2 nm parasitic SiO2 formed at each gate results in a teq of about 11.8 nm, excluding any depletion/inversion layer effects. Thus, if SiO2 is formed in the process, the teq will be increasingly limited by the thicknesses of the SiO2 layers.
To prevent the formation of SiO2, a suitable barrier layer can be interposed between the polysilicon and the desired high-κ dielectric. Such a barrier layer can be formed of one or more materials that bind oxygen in such a way as to render oxygen in the barrier layer substantially non-reactive with silicon. Oxygen so bound in the barrier layer is unable to cause a sufficient reduction in the dielectric constant of the barrier layer to approach that of SiO2.
Embodiments of the invention address formation of SiO2 between a high-κ dielectric containing oxygen and a layer of polysilicon. One or more nitride barrier layers can be inserted as an oxygen diffusion barrier between polysilicon and high-κ dielectric. In some embodiments, one or more layers can be configured to reduce the oxidation of polysilicon due to an oxide-containing high-κ dielectric. In some embodiments, one or more nitride barrier layers are formed of a silicon nitride. In various embodiments, one or more nitride barrier layers are formed of a AlN, a BN, or an oxynitride such as SiOxNy and HfOxNy. In some embodiments, the one more nitride barrier layers are a composite including two or more of a silicon nitride and a nitride such as AlN and BN. In some embodiments, at least one layer is inserted between a polysilicon gate and a high-κ dielectric that includes oxygen in a form that is non-reactive with silicon.
The first dielectric layer 106, the second dielectric layer 108, and the third dielectric layer 112 form a composite dielectric stack. Layer 106 and layer 112 can be formed of the same material or of a different material, depending on the effective dielectric constant desired between gate regions 102, 114. In some embodiments, the first dielectric layer 106 and the third dielectric layer 112 are barrier layers that prevent the diffusion of oxygen between the second dielectric layer 108 and the floating gate region 102 and the control gate region 114, respectively. In some embodiments, layer 106 and layer 112 are formed to prevent oxygen contained in the second dielectric layer 108 from reacting with the floating gate region 102 and/or with the control gate region 114, respectively. In such an embodiments, the oxygen entering layer 106 and/or 112 become sufficiently bound to the constituents in layers 106, 112 to render the oxygen substantially non-reactive with the material used for the floating gate region 102 and the control gate region 114. In some embodiments, at least one of the first dielectric layer 106 and the third dielectric layer 112 include a nitride such as a silicon nitride, an aluminum nitride and a boron nitride. In some embodiments, at least one of the first dielectric layer 106 and the third dielectric layer 112 include an oxynitride such as a SiOxNy and HfOxNy.
In some embodiments the second dielectric layer 108 includes at least one oxide of Al, Dy, Hf, Zr, Sc, La, Ta, Y, W, and Ti. In some embodiments, the second dielectric layer 108 is formed as a composite of two or more oxides of Al, Dy, Hf, Zr, Sc, La, Ta, Y, W, and Ti. In some embodiments, the layer 108 includes a nitride, such as a silicon nitride, AlN, and BN. In some embodiments, the layer 108 is formed as a composite of two or more nitrides including Si, Al, and B. In some embodiments, the layer 108 includes at least one nitride containing at least one of Si, Al, and B, and at least one oxide containing one or more of Al, Dy, Hf, Zr, Sc, La, Ta, Y, W, and Ti. In various embodiments, the layer 108 includes one or more of an oxynitride such as SiOxNy and HfOxNy, a binary nitride such as SixNy, AlN, BN, a mixed oxide such as HfAlOx, TiAlOx and ZrAlOx, a silicate such as HfSiOx, ZrSiOx, and TaSiOx, and a perovskite such as SrTiOx and LaTiOx.
The floating gate device 100 can include a well region 124, such as a p-doped well or an n-doped well, to isolate device 100 from other devices further formed in the substrate 116. Drain region 122 can be connected at terminal B to the bit line 132. The control gate 114 can be connected at terminal C to the word line 130. The source region 120 can be connected at terminal A to the source line 134 to remove charge trapped in the channel region 118 due to a voltage on the floating gate region 102. The drain region 122 and the source region 120 are n-doped regions, but may be formed as p-doped regions, depending on the device characteristics desired. Although not shown in
At block 204, a first insulator can be formed over and in substantial contact with the conductive floating gate. The first insulator can also be formed over and in substantial contact with the sidewalls of the conductive floating gate. The first insulator includes a material that is substantially oxygen free, such as a silicon nitride. The first insulator can also be a material in which any oxygen contained therein is rendered substantially non-reactive with silicon. In some embodiments, the first insulator is a diffusion barrier formed to prevent oxygen diffusion between the conductive floating gate and one or more other dielectric layers. In some embodiments, the first insulator is formed to prevent an oxidation reaction involving the conductive floating gate. The first dielectric can be formed of nitride including at least one of Si, Al, and B. In some embodiments, forming the first insulator includes forming a layer containing one or more oxynitrides of Si, Al, B, Hf, Zr, La, Ta, W, and Ti.
At block 206, a second insulator is formed over and in substantial contact with the first dielectric layer. The second insulator layer can include an oxide, a nitride or a mixture one or more oxides and one or more nitrides. The second insulator is formed with a dielectric constant that is greater than or equal to the dielectric constant of the first insulator. In some embodiments, the second insulator includes one or more oxides of Al, Dy, Hf, Zr, Sc, La, Ta, Y, W, and Ti, or one or more nitrides of Si, Al, B, Hf, Zr, La, Ta, W, and Ti. In some embodiments, forming the second layer includes forming a composite insulator of at least one oxide of Al, Dy, Hf, Zr, Sc, La, Ta, Y, W, and Ti and at least and at least one nitride of Si, Al, B, Hf, Zr, La, Ta, W, and Ti.
At block 208, a third insulator is formed over and in substantial contact with the second insulator. The third insulator can include a material that is substantially oxygen free, such as a silicon nitride, or a material in which any oxygen contained therein is rendered substantially non-reactive with silicon. The third insulator can be formed as a nitride layer containing at least one of Si, Al, and B. In some embodiments, forming the third insulator includes forming a layer containing one or more oxynitrides of Si, Al, B, Hf, Zr, La, Ta, W, and Ti.
The third insulator can be formed with a dielectric constant that is less than or equal to the second dielectric constant associated with the second insulator. In some embodiments, the third insulator is barrier layer formed to prevent oxygen diffusing from the second dielectric to a region of silicon. In some embodiments, the third insulator is a barrier formed to prevent an oxidation reaction between the second insulator and a silicon-based gate region in contact with the third dielectric layer. In some embodiments, the third insulator is formed of substantially the same material as the first insulator such that the dielectric constants of the first and third insulators are substantially equal. In an embodiment, the first, second and third insulators are formed of substantially the same material.
At block 210, a conductive control gate region is formed over and in substantial contact with the third insulator. The conductive control gate region can be formed such that the sidewalls of the control gate region are enclosed by and in substantial contact with the third insulator. The conductive control gate region can be formed of silicon, such as n-doped polysilicon or an n-doped single crystal silicon. In some embodiments, the conductive control gate region is formed of n-doped amorphous silicon. In some embodiments, the conductive control gate region is formed of substantially the same material as the conductive floating gate region.
Some examples of a circuit module include memory modules, device drivers, power modules, communication modems, processor modules and application-specific modules, and may include multilayer and multichip modules. The circuit module 600 may be a subcomponent of a variety of electronic systems, such as an imager, a digital camera, a television, game controller, a cell phone, a personal computer, a personal digital assistant, a network server such as a file server or an application server, an automobile, an industrial process control system, an aircraft and others. The circuit module 600 includes a variety of leads 620 that can be coupled to the floating gate devices 100, providing unilateral or bilateral communication and control.
One or more of the memory devices 710 can be coupled a processor 760 by a bus 745 providing bidirectional communication for some form of observation, manipulation and control or direction of inputs from or outputs to a user interface 750. Some examples of a user interface 750 include a keyboard, a pointing device, a joystick, a display, a keypad, as well as other human-machine interfaces. Examples of a processor include a microprocessor, a digital signal processor and a controller, such as a microcontroller. It should be understood that the one or more memory devices 710 in the memory module 700 can be replaced by a single integrated circuit. Furthermore, the memory module 700 may be a subcomponent of a larger electronic system, including a processor. It should also be understood by those of ordinary skill in the art after reading this disclosure that at least one of the memory modules 700 may contain an integrated circuit structure or element in accordance with embodiments of the invention, including one or more floating gate devices 100, as shown in
The Abstract is provided to comply with 37 C.F.R. Section 1.72(b) requiring an abstract that will allow the reader to ascertain the nature and gist of the technical disclosure. It is submitted with the understanding that it will not be used to limit or interpret the scope or meaning of the claims.
In the foregoing detailed description, various features are occasionally grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the subject matter require more features than are expressly recited in each claim. Rather, as the following claims reflect, invention may lie in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the detailed description, with each claim standing on its own as a separate preferred embodiment.