This application is based on and claims the benefit of priority from the prior Japanese Patent Application No. 2006-176041, filed on Jun. 27, 2006, the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to a method of forming a silicon oxide layer above a semiconductor substrate having a recess formed on its surface.
2. Description of the Related Art
There are several conventional methods of forming a silicon oxide layer on a semiconductor substrate having a recess formed on its surface, the recess being such as a shallow trench isolation (STI). One common method is to form a primary reactant on the semiconductor substrate and then perform dehydration condensation to form the silicon oxide layer. One such method is the condensation CVD method.
The condensation CVD method is described as follows. A gas containing Si, including silane (SiH4) or organic silane such as tetraethoxysilane (TEOS) or methylsilane, and an oxygen source gas such as hydrogen peroxide (H2O2) or an ozone gas are used as a raw gas. The raw gas are used to form silanol having fluidity on the semiconductor substrate and then the dehydration condensation is performed, thereby forming the silicon oxide layer (see, for example, JPH 9-251997 and JP 2002-83864).
When, for example, SiH4 and H2O2 are used as a raw gas, the SiH4 and H2O2 are first subject to the silanolization reaction to form silanol (Si(OH)4) as the primary reactant on the semiconductor substrate. Because the silanol is highly fluid, even a narrow recess can be filled flatly. The substrate is then heated (cured) in a vacuum at, for example, 350° C. in the same manufacturing equipment. The dehydration condensation reaction is thus facilitated according to formula 1, forming the silicon oxide layer,
Formula 1
Si(OH)4→SiO2+2H2O
The condensation CVD method exhibits better embeddability than the HDP-CVD. The method provides, however, an insufficient withstand voltage of the silicon oxide layer embedded in the recess. The insufficient with stand voltage may degrade the characteristics of the semiconductor device.
A method of forming a silicon oxide layer according to a first aspect of the present invention comprises: supplying at least a gas containing Si as a raw gas to a semiconductor substrate having a recess formed on its surface to form a primary reactant on the surface, then performing dehydration condensation to form a silicon oxide layer above the semiconductor substrate; removing a part of the silicon oxide layer until a portion of the silicon oxide layer formed in the recess that has a lower density than the silicon oxide layer formed in a vicinity of the surface is at least partially exposed; and supplying a gas containing Si to the silicon oxide layer having a lower density.
A method of forming a silicon oxide layer according to a second aspect of the present invention comprises supplying at least a gas containing Si as a raw gas to a semiconductor substrate having a recess formed on its surface to form a primary reactant on the surface, then performing dehydration condensation to form a silicon oxide layer above the semiconductor substrate, wherein an energy beam is applied during the primary reactant is formed.
A method of forming a silicon oxide layer according to a third aspect of the present invention comprises supplying at least a gas containing Si as a raw gas to a semiconductor substrate having a recess formed on its surface to form a primary reactant on the surface, then performing dehydration condensation to form a silicon oxide layer above the semiconductor substrate, wherein a dehydration condensation accelerator is supplied during the primary reactant is formed.
A method of forming a silicon oxide layer according to a fourth aspect of the present invention comprises supplying at least a gas containing Si as a raw gas to a semiconductor substrate having a recess formed on its surface to form a primary reactant on the surface, then performing dehydration condensation to form a silicon oxide layer on the semiconductor substrate, Wherein the semiconductor substrate is heated while exposing the primary reactant to oxygen plasma after the primary reactant is formed.
A method of forming a silicon oxide layer according to a first embodiment of the present invention will be described in detail with reference to the accompanying drawings.
A description is now given of a method of forming a silicon oxide layer according to the first embodiment using the above manufacturing equipment. Referring to
With the semiconductor substrate 22 being cooled to, for example, 0 to 5° C., the condensation CVD method is implemented, using a gas containing Si such as SiH4 and an oxygen source gas such as H2O2 as the raw gas, to form silanol, filling the STI 30. Specifically, the SiH4 and H2O2 are supplied through the supply openings 18 and 20 into the reaction chamber 10. The SiH4 and H2O2 may cause a silanolization reaction (such as SiH4+4H2O2→Si(OH)4+4H2O). The reaction forms the silanol over the semiconductor substrate having the thin silicon oxide layer 32 formed thereon. Although in the first embodiment, the semiconductor substrate 22 is cooled to 0 to 5° C. as described above, the semiconductor substrate 22 may be maintained at a temperature range from −10 to 15° C. This temperature range is acceptable to allow silanol having fluidity to adhere to the substrate surface, allowing silanol to fill closely the STI 30. Then, under the vacuum condition, the semiconductor substrate 22 is transferred to another reaction chamber (not shown). In the chamber, the substrate 22 is heated (cured) in a vacuum by a heater and the like at, for example, 350° C. The dehydration condensation reaction is thus facilitated, forming the silicon oxide layer on the substrate 22.
The silicon oxide layer thus formed by the condensation CVD method undergoes volume contraction from the dehydration condensation. Referring to
The lower density area 36 is then subject to improvement. The improvement may start with supplying SiH4 into the reaction chamber 10 to impregnate the lower density area 36 with SiH4. The lower density area 36 has more remaining uncross-linked Si—OH groups than the dense layer 34. With no H2O2 being supplied, therefore, SiH4 impregnated into the lower density area 36 may react with the uncross-linked Si—OH groups, forming SiO2. The lower density area 36 may thus reduce its density nonuniformity, as shown in
Note that the steps to form silanol and the subsequent steps such as the curing process may be performed in the same manufacturing equipment. The method of forming a silicon oxide layer according to the first embodiment may be applied not only to fill the STI but also to fill between Al lines formed by RIE and the like. In the method of forming a silicon oxide layer according to the first embodiment, the improvement may not use the gas containing Si that is used to form the silanol, and may use different gas containing Si such as organic silane such as TEOS or methylsilane.
The condensation CVD method generally exhibits better embeddability. The method undergoes, however, volume contraction from the dehydration condensation reaction after silanol is formed, filling the recesses. The volume contraction may cause the density reduction of the silicon oxide layer that is embedded into the recesses by the condensation CVD method. The volume contraction may also cause a density nonuniformity of the silicon oxide layer in the recesses. The recesses may thus have a lower density area formed therein. The volume contraction may also peel the silicon oxide layer off the inside of the recesses. Particularly, such problems have become more pronounced as the recess becomes smaller or the aspect ratio (depth/opening width of the groove) becomes larger. When, as described above, the silicon oxide layer has the lower density area formed therein or experiences peeling, the resistance to chemical solution may reduce or roughness may occur after the processings. The subsequent processings may thus be adversely affected, or the withstand voltage may be reduced, thereby degrading the characteristics of the semiconductor device. Such problems may be solved by the method of forming a silicon oxide layer according to the first embodiment by improving the lower density area to reduce the density nonuniformity in the lower density area, thereby improving the layer to be the dense silicon oxide layer.
A method of forming a silicon oxide layer according to a second embodiment of the present invention will be described in detail with reference to the accompanying drawings.
A description is now given of a method of forming a silicon oxide layer according to the second embodiment using the manufacturing equipment. Referring to
The condensation CVD method is implemented, using SiH4 and H2O2 as the raw gas, to form a silicon oxide layer, filling between the Al lines 42. The method of forming a silicon oxide layer according to the second embodiment differs from the that of the first embodiment in that during the silanol is formed, the microwave irradiation portion 38 applies the microwave in the reaction chamber 10. Referring to
As described above, in the method of forming a silicon oxide layer according to the second embodiment, the silicon oxide layer is formed by the condensation CVD method using the application of the microwave. Alternatively, however, an electron beam irradiation portion or an ultraviolet light irradiation portion may be provided, for example, to apply the electron beam or ultraviolet light. The method of forming a silicon oxide layer according to the second embodiment may be applied not only to fill the recess but also to form, on a flat substrate, a dense silicon oxide layer. Further, the method of forming a silicon oxide layer according to the second embodiment may be applied not only to fill between the Al lines formed by RIE but also to fill the STI and the like.
The problems with the condensation CVD described above may be solved by the method of forming a silicon oxide layer according to the second embodiment by forming the primary reactant such as silanol using the application of the energy beam, thereby forming the homogeneous and dense silicon oxide layer.
A method of forming a silicon oxide layer according to a third embodiment of the present invention will be described in detail with reference to the accompanying drawings. The manufacturing equipment is the same as that used in the first embodiment. Referring to
The method of forming a silicon oxide layer according to the third embodiment may be applied not only to fill the recess but also to form, on a flat substrate, a dense silicon oxide layer. In the method of forming a silicon oxide layer according to the third embodiment, the dehydration condensation accelerator may be, other than the ammonia, a chemical compound including an ammonium group, such as amine such as ethylenediamine. The dehydration condensation accelerator may be supplied after it is dissolved in aqueous solution of H2O2 and may then be evaporated. The method of forming a silicon oxide layer according to the third embodiment may be applied not only to fill the STI but also to fill between the Al lines formed by RIE and the like.
The problems with the condensation CVD described above may be solved by the method of forming a silicon oxide layer according to the third embodiment by forming the primary reactant such as silanol using the supply of the dehydration condensation accelerator, thereby forming the homogeneous and dense silicon oxide layer.
A method of forming a silicon oxide layer according to a fourth embodiment of the present invention will be described.
A description is now given of a method of forming a silicon oxide layer according to the fourth embodiment using the manufacturing equipment. Referring to
In the curing process, the substrate 60 may be exposed to the oxygen plasma, and then be annealed, thereby reducing the volume contraction in the annealing. Compared to the conventional curing process that is performed, for example, under the nitrogen atmosphere, the silicon oxide layer is less likely to be peeled off and to have the lower density area, thereby causing less dissolution during the chemical solution cleaning. Particularly, with the substrate 60 being exposed to the oxygen plasma, the substrate 60 may be heated (cured) more effectively at low temperatures of 300° C. or less, particularly 150° C. or less.
The inventors compared a plurality of silanol layers formed at the same condition by providing the layers with the different curing processes. One layer was subject to the conventional high temperature curing process. Another was the low temperature curing process with the layer being exposed to the oxygen. Still another was the low temperature curing process with the layer being exposed to the oxygen plasma. Specifically, one layer was cured with it being exposed to the nitrogen at 600° C. for two minutes, and was then annealed at 900° C. for one hour. The cured layer thickness was 100 nm and the annealed layer thickness was 90 nm. Another layer was cured with it being exposed to the oxygen at 100° C. for one minute, and was then annealed at 900° C. for one hour. The cured layer thickness was 115 nm and the annealed layer thickness was 95 nm. Still another layer was cured with it being exposed to the oxygen plasma at 250 mTorr and 1000 W at 100° C. for five minutes, and was then annealed at 900° C. for one hour. The cured layer thickness was 110 nm and the annealed layer thickness was 105 nm. Such comparison experiments showed that the lower temperature and shorter time curing process exhibited less volume contraction, and the curing process under exposure to the oxygen plasma exhibited even less volume contraction.
The curing process under exposure to the oxygen plasma may be combined with the above-mentioned first to third embodiments. Specifically, in the first to third embodiments, after the silanol is formed, the curing process may be performed under exposure to the oxygen plasma. The method of forming a silicon oxide layer according to the fourth embodiment may be applied not only to fill the STI, but also to fill between the Al lines formed by RIE and the like. In the method of forming a silicon oxide layer according to the fourth embodiment, the annealing process may be performed at higher temperatures than the curing process.
Note that in the method of forming a silicon oxide layer according to the first to fourth embodiments, the SiH4 and H2O2 are used as the raw gas in the condensation CVD method, but the present invention is not limited thereto. The gas containing Si may include, for example, organic silane such as TEOS or methylsilane, and the oxygen source gas may include ozone gas or the like.
Number | Date | Country | Kind |
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2006-176041 | Jun 2006 | JP | national |