This application is based upon and claims the benefit of priority from prior Japanese patent application JP 2006-342143, filed on Dec. 20, 2006, the disclosure of which is incorporated herein by reference in its entirety.
This invention relates to a method of producing a semiconductor device and, in particular, to a method of producing a semiconductor device having a trench gate.
For example, recent miniaturization of a DRAM (Dynamic Random Access Memory) is remarkable. Following the miniaturization of the DRAM, a gate of a transistor in a memory cell inside the DRAM is also miniaturized. Following the miniaturization of the gate, the problem of a short-channel effect of the transistor is exposed. Under the circumstances, the technique called a “trench gate” becomes a mainstream in which a groove (trench) is formed under the gate and the bottom of the groove is used as a channel so as to assure a sufficient and necessary channel length. In the “trench gate”, there is a problem of high Si burrs produced in the groove in a direction parallel to word lines (i.e., parallel to gate electrodes) during formation of the groove. In detail, the Si burrs are produced in the groove on a surface adjacent to STI (Shallow Trench Isolation).
In the existing technique, the Si burrs are removed by oxidizing the Si burrs into an oxide film and then wet-etching the oxide film, as will be described below as the related art. In this method, however, the amount of oxidization and the amount of wet etching must be increased depending upon the thickness of the burrs. Excessive wet etching results in a difference in surface levels, causing a serious influence.
Referring to
Referring to
On the oxide film 21 on the silicon substrate 10 and on the STI buried oxide film 20, a SiN (silicon nitride) film (will later be illustrated) of Si3N4 is formed. A part of the SiN film is selectively removed by dry etching in a normal gate forming region 50 where a normal gate region of the memory cell is to be formed later. Consequently, the oxide film 21 on the silicon substrate 10 is exposed. This state is illustrated in
Referring to
Referring to
Referring to
Herein, the reason why the Si burrs 74 are produced will be described.
Turning back to
Next, attention will be directed to a part B in
Thus, the Si burrs are left because of the above-mentioned two reasons.
When the Si burrs are left unremoved, a parasitic channel is formed to cause a hump phenomenon. Therefore, the Si burrs must be removed.
Referring to
Next referring to
Next referring to
As described above, in the existing technique, the Si burrs 74 produced upon formation of the trench 72 by dry etching as shown in
Japanese Unexamined Patent Application Publication No. 2004-087738 (JP-A) (Patent Document 1) discloses use of a mixed gas of SF6/O2/SiF4 as an etching gas for trench etching of a Si substrate (see Example 2).
Japanese Unexamined Patent Application Publication No. H06-163478 (JP-A) (Patent Document 2) discloses use of a mixed gas of SF6/HBr as an etching gas upon forming a trench in a silicon substrate by etching (see Comparative Example 2 in
As described above, in order to remove the Si burrs, the existing technique adopts the method including thermal oxidization of the Si burrs and wet etching of the oxide film. However, in order to completely remove the Si burrs which are thick and high, the thermal oxidization and the wet etching of the oxide film must be excessively carried out. This results in recession of the STI oxide film and occurrence of a step on a surface. As a consequence, there arises a problem of increase in word line capacitance. Under the circumstances, there is a demand for a method of removing Si burrs using other means.
It is an exemplary object of this invention to provide a method of producing a semiconductor device capable of removing semiconductor burrs without causing an increase in word line capacitance.
It is another exemplary object of this invention to provide a method of producing a semiconductor device capable of preventing occurrence of semiconductor burrs without causing an increase in word line capacitance.
Methods according to this invention are as follows:
(1) A method of producing a semiconductor device, comprising an etching step of dry etching a semiconductor substrate by the use of an etching gas in which an etch rate in a lateral direction is greater than an etch rate in a depth direction.
(2) The method according to the above-mentioned (1), further comprising:
a STI (Shallow Trench Isolation) forming step of forming a STI layer on a surface of the semiconductor substrate and a groove forming step of forming a groove for a trench gate by dry etching on the surface of the semiconductor substrate in an area surrounded by the STI layer;
the etching step being a step of dry etching, by the use of the etching gas, the semiconductor substrate with the groove formed thereon.
(3) The method according to the above-mentioned (2), wherein:
the etching step is a step intended to remove semiconductor burrs produced in the groove on groove surfaces adjacent to the STI layer during formation of the groove on the surface of the semiconductor substrate;
the etching step being a step of removing the semiconductor burrs by dry etching using, as the etching gas, a mixed gas having a gas flow rate ratio such that an etch rate ratio R1/R2 is smaller than 1, where R1 is the etch rate in the depth direction in a section of the groove in a direction parallel to word lines and R2 is the etch rate in the lateral direction in the section of the groove in the direction parallel to the word lines;
the mixed gas consisting essentially of SF6 and SiF4.
(4) The method according to the above-mentioned (2), wherein:
the etching step is a step intended to remove semiconductor burrs produced in the groove on groove surfaces adjacent to the STI layer during formation of the groove on the surface of the semiconductor substrate;
the etching step being a step of removing the semiconductor burrs by dry etching using, as the etching gas, a mixed gas having a gas flow rate ratio such that an etch rate ratio R1/R2 is smaller than 1, where R1 is the etch rate in the depth direction in a section of the groove in a direction parallel to word lines and R2 is the etch rate in the lateral direction in the section of the groove in the direction parallel to the word lines and that an etch rate ratio R3/R4 is equal to or greater than 1, where R3 represents an etch rate in a depth direction in a section of the groove in a direction perpendicular to the word lines and R4 represents an etch rate in a lateral direction in the section of the groove in the direction perpendicular to the word lines;
the mixed gas consisting essentially of SF6 and SiF4.
(5) A method of producing a semiconductor device, comprising a STI (Shallow Trench Isolation) forming step of forming a STI layer on a surface of a semiconductor substrate and a groove forming step of forming a groove for a trench gate by dry etching on the surface of the semiconductor substrate in an area surrounded by the STI layer wherein:
the groove forming step is a step of forming the groove in the area by dry etching using a mixed gas consisting essentially of SF6 and HBr without producing semiconductor burrs in the groove on groove surfaces adjacent to the STI layer.
(6) The method according to claim 5, wherein the groove forming step uses, as the mixed gas, a mixed gas having a gas flow rate ratio FR satisfying:
0.2<FR<4
where FR is given by (SF6 flow rate)/(HBr flow rate).
The above-referred Patent Documents 1 and 2 do not disclose that, upon forming a groove for a trench gate, Si burrs are produced in the groove on a surface adjacent to a STI buried oxide film and that an etching gas, in which an etch rate in a lateral direction is greater than an etch rate in a depth direction, is used in order to remove the Si burrs. Further, the Patent Documents 1 and 2 do not disclose that an etching gas is used which has a SF6/SiF4 gas flow rate ratio (mixing ratio) such that the etch rate in the lateral direction is greater than the etch rate in the depth direction. Still further, the Patent Documents 1 and 2 do not disclose prevention of occurrence of the Si burrs upon forming the groove for the trench gate and a specific SF6/HBr gas flow rate ratio capable of preventing occurrence of the Si burrs.
In this invention, dry etching is performed by the above-mentioned composition containing SF6 as an isotropic etching component and SiF4 as a deposition gas added thereto. Thus, without damaging or deforming the shape of the groove, the Si burrs produced in the groove on the surface adjacent to the STI layer can be removed. Accordingly, no increase in capacitance occurs unlike the above-mentioned related art.
Further, in this invention, dry etching is performed by the above-mentioned composition containing SF6 as an isotropic etching component and HBr generating a low vapor pressure etching product. Thus, the groove can be formed on the surface of the semiconductor substrate without producing Si burrs in the groove on the surface adjacent to the STI layer. Again, no increase in capacitance occurs unlike the above-mentioned related art.
Now, this invention will be described with reference to the drawing.
Referring to
Thus, a method of producing a semiconductor device comprises an etching step of dry etching a semiconductor substrate by the use of an etching gas in which a lateral-direction etch rate (that is, an etch rate in a lateral direction) is greater than a depth-direction etch rate (that is, an etch rate in a depth direction).
In detail, dry etching using the above-mentioned composition containing SF6 and SiF4 added thereto is carried out as a step illustrated in
Referring to
Preferably, the Si burrs 74 are removed by dry etching using a mixed gas containing SF6 and SiF4 and having a gas flow rate ratio such that an etch rate ratio R1/R2 is smaller than 1 where R1 represents a depth-direction etch rate in a section of the groove 72 in a direction parallel to word lines (i.e., a direction parallel to gate electrodes as described above) and R2 represents a lateral-direction etch rate in the section of the groove 72 in the direction parallel to the word lines and that an etch rate ratio R3/R4 is equal to or greater than 1 where R3 represents a depth-direction etch rate in a section of the groove 72 in a direction perpendicular to the word lines (i.e., a direction perpendicular to the gate electrodes) and R4 represents a lateral-direction etch rate in the section of the groove 72 in the direction perpendicular to the word lines.
When the abovementioned burr removing step in
In a second embodiment of this invention, dry etching is performed by the use of a composition containing SF6 as an isotropic etching component and HBr generating a low vapor pressure etching product (specific numerical values of gas flow rates will later be described). Thus, as illustrated in (b) in
Specifically, the dry etching using the above-mentioned composition containing SF6 and HBr added thereto is carried out as the step in
Now, examples of this invention will be described.
In Example 1, a SF6/SiF4 gas mixing ratio capable or efficiently removing Si burrs is determined.
This example is for use in implementing the first embodiment.
The burr removing step is required to meet the following requirements:
(1) the lateral-direction etch rate R2 is as higher as possible than the depth-direction etch rate R1 in the section of the groove 72 in the direction parallel to the word lines in
(2) microloading is large and the etch rate is low with respect to a fine pattern.
In order to determine an appropriate condition satisfying these requirements, an experimental test is carried out.
A basic condition is as follows.
SF6/SiF4/O2=50/180/5(sccm), 4 Pa, 15 sec
Examination has been made about the relationship between the SF6/SiF4 flow rate and the ratio of the depth-direction etch rate and the lateral-direction etch rate.
From the result illustrated in
In this example, etching was carried out at 60° C. It is found out that, by changing the temperature in a range from −5° C. to 150° C., the etch rate ratio can be controlled with a certain degree of freedom.
In Example 2, Si burrs produced during formation of the groove using a HBr/Cl2/O2 gas are removed by dry etching under the condition determined in Example 1.
This example is also used for implementing the first embodiment.
At first, a field (STI buried oxide film) is formed. Thereafter, using a mask of a reversed gate pattern, a groove having a depth of 150 nm is formed in a Si substrate by a HBr/Cl2/O2 gas. An etching apparatus is a commercially-sold ICP (Inductive Coupled Plasma) etching apparatus. The etching condition is as follows (typical STI silicon etching condition).
Cl2/HBr/O2=90/80/5(sccm), 4 Pa, 15 sec
At this time, the Si burrs produced in the direction parallel to the word lines have a height of 115 nm and a base thickness of 30 nm. By carrying out the etching step of removing Si burrs as optimized in Example 1, the Si burrs in the direction parallel to the word lines could be removed substantially without damaging or deforming the shape of the groove in the direction perpendicular to the word lines. After removing the Si burrs, the bottom of the groove has a slightly rounded shape. However, after gate formation, the bottom is substantially flat. Therefore, a factor disturbing transistor characteristics, such as hump, is not caused.
In Example 3, groove Si etching without occurrence of Si burrs is carried out by the use of a SF6/HBr gas.
This example is used for implementing the second embodiment.
From the result of Example 2, the function of adjusting the shape of the bottom of the groove by isotropic etching using SF6 and deposition using SiF4 has been confirmed. Therefore, consideration is next made about a technique of performing groove Si etching without producing the Si burrs. As a gas for use with SF6, SiF4 is insufficient in vertical etching rate. Therefore, a HBr gas is used herein which serves as a vertical etching gas and generates an etching product having a relatively low vapor pressure. The etching condition is as follows. Optimization of a gas mixing ratio alone was carrier out.
SF6/HBr=40/140(sccm), 1 Pa, 20 sec (center condition)
Herein, as evaluation items, the thickness of the Si burrs and a boring amount in the direction perpendicular to the word lines are selected. The result of test is shown in
The optimum value is judged as SF6HBr=40/140 (sccm). The ratio of SF6/HBr=50/130 (sccm) is also adoptable as a specific example.
Assembling the above-mentioned test results and other test results with respect to the flow rate ratio, an appropriate range of the flow rate ratio is determined. Herein, the flow rate ratio (SF6 flow rate)/(HBr flow rate) is represented by FR. By dry etching using a mixed gas having the gas flow rate ratio FR in the following range, the groove 72 can be formed on the surface of the semiconductor substrate without producing Si burrs in the groove 72 on the surface adjacent to the STI buried oxide film 20.
0.2<FR<0.4
The similar test was carried out in case where SiF4 was used instead of HBr. Depending upon the condition, this mixed gas is usable. However, in case of SiF4, the vertical etch rate is insufficient. Therefore, the etching time is inevitably lengthened to cause some disadvantage.
Although this invention has been described in conjunction with a few exemplary embodiments thereof this invention may be modified in various other manners.
Number | Date | Country | Kind |
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2006-342143 | Dec 2006 | JP | national |