This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2008-130568, filed on May 19, 2008, the entire contents of which are incorporated herein by reference.
In recent years, in accordance with miniaturization of a semiconductor element, a method of forming a pattern having a dimension smaller than a resolution limit of lithography (threshold exposure linewidth) is required. As one of such methods, a method is known in which sidewall patterns are formed on side faces of a dummy pattern (core material) and a workpiece film is etched using the sidewall patterns as a mask. This method, for example, is disclosed in JP-A-2006-303022.
According to the conventional method disclosed in JP-A-2006-303022, etc., after forming the sidewall patterns, the dummy pattern between the sidewall patterns is removed by wet etching treatment, thereby forming a microscopic mask composed of the sidewall patterns. Recently, further miniaturization of a pattern dimension and further improvement of dimensional precision have been required to such pattern forming methods using the sidewall patterns.
However, according to the conventional method disclosed in JP-A-2006-303022, etc., accuracy of the mask pattern may be deteriorated by the inclination of the sidewall pattern due to surface tension acting in chemical solution used for removing the dummy pattern or a stress generated in the sidewall pattern or the dummy pattern, etc.
A method of fabricating a semiconductor device according to one embodiment includes: forming a core material on a workpiece; forming a coating film comprising an amorphous material so as to cover an upper surface and side faces of the core material; crystallizing the coating film by applying heat treatment; forming a sidewall mask by removing the crystallized coating film while leaving a portion thereof located on the side faces of the core material; removing the core material after forming the sidewall mask; and etching the workpiece using the sidewall mask as a mask after removing the core material.
A method of fabricating a semiconductor device according to another embodiment includes: forming a core material on a workpiece; forming a coating film comprising an amorphous material so as to cover an upper surface and side faces of the core material; forming a sidewall mask by removing the coating film while leaving a portion thereof located on the side faces of the core material; crystallizing the sidewall mask by applying heat treatment; removing the core material after crystallizing the sidewall mask; and etching the workpiece using the sidewall mask as a mask after removing the core material.
A method of fabricating a semiconductor device according to another embodiment includes: forming a core material on a workpiece; forming a coating film comprising an amorphous material so as to cover an upper surface and side faces of the core material; forming a stress film including a compressive stress on the coating film, and crystallizing the coating film by heat applied at the time of forming the stress film; applying etching to the coating film and the stress film, thereby forming a sidewall mask on side faces of the core material, the sidewall mask comprising the coating film and the stress film thereon; removing the core material after forming the sidewall mask; and etching the workpiece using the sidewall mask as a mask after removing the core material.
Firstly, as shown in
Here, the workpiece films 1a and 1b are, e.g., a gate material film or a hard mask on an object to be processed. Alternatively, the workpiece films 1a and 1b may be a film composed of plural layers, e.g., a control electrode film, an interelectrode insulating film and a floating gate electrode film composing a stack gate structure of a flash memory. Furthermore, the semiconductor substrate itself may be an object to be processed (workpiece).
In addition, the first film 2 is made of TEOS (Tetraethoxysilane), SiO2, SiN or C, etc., and a film thickness thereof is determined based on a selectivity of the workpiece film 1b with respect to a sidewall mask 7 formed in a posterior process, etc. Note that, depending on material properties of the first film 2, after forming a film for ensuring an etching selectivity to the resist 3 on the first film 2, the resist 3 may be pattern-formed thereon.
In addition, the resist 3 is made of, e.g., polycrystalline Si. In this case, the resist 3 is formed by patterning using a lithography method and a RIE (Reactive Ion Etching) method after forming a polycrystalline Si film by the LPCVD method. In addition, a predetermined pattern of the resist 3 is, e.g., line-and-space.
Next, as shown in
At this time, the etching is also applied to the workpiece film 1b until a trench with a predetermined depth is formed. As a result, a region having the core material formed thereon and stepped portions 9 formed in other regions are formed in the workpiece film 1b. Here, the predetermined depth is a depth that does not adversely affect a posterior process shape even though it is preferably deeper than a depth of a trench formed by unintentional removal of the workpiece film 1b due to a problem of processing accuracy, etc., at the time of applying etching to the first film 2.
Next, as shown in
Here, the sliming treatment is carried out by wet etching, dry etching, or a combination of the wet etching and the dry etching. Then, the stepped portion 9 in the workpiece film 1b is exposed by the slimming treatment.
Next, as shown in
Next, as shown in
Here, for example, when the amorphous film 5 is amorphous Si, the amorphous film 5 is crystallized by the heat treatment at about 600° C. or more and is transformed into polycrystalline Si as the crystal film 6. Furthermore, the heat treatment is preferably carried out at about 650° C. or more in order to effectively crystallize the amorphous film 5 that is amorphous Si. In addition, the upper limit of the heat treatment temperature may be a temperature that does not adversely affect other members on the semiconductor device, e.g., may be about 950° C. which is a temperature not deteriorating film quality of a gate oxide film.
Meanwhile, when the amorphous film 5 is amorphous alumina, the amorphous film 5 is crystallized by the heat treatment at about 900° C. or more and is transformed into polycrystalline alumina as the crystal film 6. In addition, the upper limit of the heat treatment temperature may be a temperature that does not adversely affect other members on the semiconductor device, e.g., may be about 950° C. which is a temperature not deteriorating film quality of a gate oxide film. The polycrystalline alumina in this case is often transformed into γ-Al2O3 having a spinel type structure.
Next, as shown in
Next, as shown in
When the core material 4 is removed, the chemical solution used for wet etching enter into a region where the core material 4 was formerly located, and a force gravitating towards each other acts on the sidewall masks 7 located on both sides of the region where the core material 4 was formerly located due to influence of the surface tension acting in the chemical solution, etc. However, in the present embodiment, since the compressive stress included in the sidewall mask 7 interrupts the force gravitating towards each other that acts on the sidewall masks 7 located on both sides of the region where the core material 4 was formerly located, it is possible to suppress gradient deformation of the sidewall mask 7 caused by the surface tension of the chemical solution, etc.
Next, as shown in
Here, similarly to the above described present embodiment, “with crystallization” in
In addition, displacement [nm] in
In addition, when the magnitude of the compressive stress f4 varies depending on the heat treatment temperature, the heat treatment temperature is preferably a temperature by which the compressive stress f4 is reduced. For example, when TEOS is used as the material of the core material 4, the force f5 is maximized at the heat treatment temperature of about 700° C. and the force f5 decreases according to increase of the heat treatment temperature. Therefore, when TEOS is used as the material of the core material 4, it is possible to reduce the compressive stress f4 by increasing the heat treatment temperature as much as possible.
Therefore, as for the heat treatment temperature, it is preferable to select a temperature by which the magnitude of the force f1 in the sidewall mask 7 (preferably large) and the magnitude of the compressive stress f4 in the core material 4 (preferably small) are well-balanced. When amorphous Si is used as a material of the amorphous film 5 (the sidewall mask is polycrystalline Si) and TEOS is used as the material of the core material 4, it is preferable to carry out the heat treatment at 750-850° C.
According to the first embodiment, by forming the sidewall mask 7 including a compressive stress, it is possible to suppress the gradient deformation of the sidewall mask 7, and thereby accurately transferring the pattern including a microscopic line-and-space pattern to the workpiece films 1a and 1b.
In addition, it is possible to suppress the gradient deformation of the sidewall mask 7 more effectively by forming the stepped portion 9 in the workpiece film 1b.
The present embodiment is different from the first embodiment in the timing of crystallizing the amorphous film 5. Note that, the explanation will be omitted or simplified for the points same as the first embodiment.
Firstly, the processes until the process, shown in
Next, as shown in
Next, as shown in
Subsequently, the processes after the process, shown in
According to the second embodiment, it is possible to obtain the same effect as the first embodiment even when the sidewall mask 7 is formed by crystallizing the amorphous film 5 after shaping the amorphous film 5 into a sidewall shape.
The present embodiment is different from the first embodiment in that a stress film is formed on the side face of the sidewall mask 7. Note that, the explanation will be omitted or simplified for the points same as the first embodiment.
Firstly, the processes until the process, shown in
Next, as shown in
Next, as shown in
Subsequently, the processes after the process, shown in
According to the third embodiment, by forming the sidewall mask 7 so as to have a structure having the stress film 8 on the side face thereof, it is possible to suppress the gradient deformation of the sidewall mask 7 more effectively, thereby accurately transferring the pattern including a microscopic line-and-space pattern to the workpiece films 1a and 1b.
It should be noted that the present invention is not intended to be limited to the above-mentioned first to third embodiments, and the various kinds of changes thereof can be implemented by those skilled in the art without departing from the gist of the invention.
For example, instead of the amorphous film 5, it is possible to use a film made of a crystal of which crystalline phase is transformed by heat treatment. When a compressive stress is generated in the crystal by crystalline phase transition, it is possible to form the sidewall mask 7 including a compressive stress by using such a crystal.
Furthermore, it is possible to arbitrarily combine the configurations of the above-mentioned first to third embodiments without departing from the gist of the invention.
Number | Date | Country | Kind |
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2008-130568 | May 2008 | JP | national |
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Number | Date | Country |
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2006-303022 | Nov 2006 | JP |
Number | Date | Country | |
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20090286401 A1 | Nov 2009 | US |