This invention relates to methods for producing silicon nitride films and more particularly relates to methods for producing silicon nitride films by vapor-phase growth, such as chemical vapor deposition (CVD).
Silicon nitride films have excellent barrier properties and an excellent oxidation resistance and as a consequence are used in the fabrication of microelectronic devices, for example, as an etch-stop layer, barrier layer, or gate insulation layer, and in oxide/nitride stacks.
Plasma-enhanced CVD (PECVD) and low-pressure CVD (LPCVD) are the methods primarily used at the present time to form silicon nitride films.
PECVD is typically carried out by introducing a silicon source (typically silane) and a nitrogen source (typically ammonia, but more recently nitrogen) between a pair of parallel plate electrodes and applying high-frequency energy across the electrodes at low temperatures (about 300° C.) and low pressures (0.001 torr to 5 torr) in order to induce the generation of a plasma from the silicon source and nitrogen source. The active silicon species and active nitrogen species in the resulting plasma react with each other to produce a silicon nitride film. The silicon nitride films formed in this manner by PECVD typically do not have a stoichiometric composition and are also hydrogen rich and accordingly exhibit a low film density, a poor step coverage, a fast etching rate, and a poor thermal stability.
LPCVD uses low pressures (0.1 to 2 torr) and high temperatures (800° C. to 900° C.) and produces silicon nitride films with a quality superior to that of the silicon nitride films produced by PECVD. At the present time silicon nitride is typically produced by LPCVD by the reaction of dichlorosilane and gaseous ammonia. However, ammonium chloride is produced as a by-product in the reaction of dichlorosilane and gaseous ammonia in this LPCVD procedure: this ammonium chloride accumulates in and clogs the reactor exhaust lines and also deposits on the wafer. Moreover, existing LPCVD technology suffers from a slow rate of silicon nitride film growth and has a high thermal budget. In order to reduce this thermal budget for the production of silicon nitride films, a method has very recently been developed that produces silicon nitride films by reacting ammonia with hexachlorodisilane used as a silicon nitride precursor. This method, however, suffers from a pronounced exacerbation of the problems cited above due to the large amounts of chlorine present in hexachlorodisilane. Silicon-containing particles are also produced by this method, which results in a substantial reduction in the life of the exhaust lines. Finally, this method can provide high-quality silicon nitride films (good step coverage ratio, low chlorine content) at excellent growth rates at a reaction temperature of, for example, 600° C., but these characteristics suffer from a pronounced deterioration when a reaction temperature ≦550° C. is used.
The use of carbon-containing volatile silazanes, azidosilazanes, and aminosilanes as silicon nitride precursors has been proposed in order to solve the problems cited above (refer, for example, to non-patent references 1 and 2). However, these silicon nitride precursors, whether used by themselves or in combination with ammonia, result in the incorporation of SiC and/or large amounts of carbon in the silicon nitride film product.
(Non-patent reference 1)
Grow et al., Mater. Lett. 23, 187, 1995
(Non-patent reference 2)
Levy et al., J. Mater. Res., 11, 1483, 1996
The problem addressed by this invention, therefore, is to provide a vapor-phase growth method for producing silicon nitride films that can produce silicon nitride films with improved film characteristics and that can do so even at relatively low temperatures, without the accompanying generation of ammonium chloride, and without significant admixture of carbonaceous contaminants into the film product.
According to a first aspect of this invention, there is provided a method for producing silicon nitride films by vapor-phase growth, said method being characterized by
According to a second aspect of this invention, there is provided a method for producing silicon nitride films by vapor-phase growth, said method being characterized by
This invention is explained more specifically hereinbelow.
This invention, which relates to methods for forming silicon nitride films on substrates by a vapor-phase growth procedure such as CVD, employs trisilylamine ((H3Si)3N) and/or a silylhydrazine as silicon nitride precursors. These precursors produce a silicon nitride film by a vapor-phase reaction with a hydrazine. Among these precursors, the silylhydrazine can form a silicon nitride film by itself by thermal decomposition.
The silylhydrazine used by this invention encompasses silylhydrazine as defined by formula (I)
H3Si(Ra)N—N(Rb)Rc (I)
wherein Ra, Rb, and Rc are each independently selected from silyl, the hydrogen atom, methyl, ethyl, and phenyl.
The hydrazine that is reacted with the aforementioned precursors encompasses hydrazines defined by formula (II)
H(R1)N—N(R2)R3 (II)
wherein R1, R2, and R3 are each independently selected from the hydrogen atom, methyl, ethyl, and phenyl.
The method for producing silicon nitride film by reacting a hydrazine with the aforementioned precursors (CVD procedure) will be described first. In this case, a precursor gas, a hydrazine gas, and optionally an inert dilution gas are fed into a reaction chamber that holds at least one substrate (particularly a semiconductor substrate such as a silicon substrate) and a silicon nitride film is formed on the substrate(s) by reaction between the precursor gas and hydrazine gas.
The interior of the reaction chamber can be maintained at a pressure from 0.1 torr to 1,000 torr during the reaction between the precursor gas and hydrazine gas, while maintenance of a pressure of 0.1 torr to 10 torr within the reaction chamber is preferred.
The reaction between the precursor gas and hydrazine gas can generally be carried out at temperatures (CVD reaction temperature) no greater than 1,000° C. However, almost no production of silicon nitride occurs at temperatures below 300° C. Accordingly, the reaction between precursor gas and hydrazine gas can generally be carried out at 300° C. to 1,000° C. This precursor and the hydrazine can produce silicon nitride at sufficiently high growth rates (film formation rate) even at low temperatures of 400° C. to 700° C. In addition, when the CVD reaction temperature is 300° C. to 500° C., step coverage ratios, for example, of at least about 0.8 can be achieved even for apertures with an aspect ratio of 10. The step coverage ratio can be defined as the value afforded by dividing the minimum film thickness at a step feature by the film thickness in a flat or planar region. The CVD reaction temperature is usually the temperature of or near the substrate on which the silicon nitride is formed.
The hydrazine gas and precursor gas can be fed into the reaction chamber at a hydrazine/precursor flow rate ratio generally of no more than 100. While silicon nitride can be produced even when the hydrazine/precursor flow rate ratio exceeds 100, hydrazine/precursor flow rate ratios in excess of 100 are generally uneconomical. Preferred values of the hydrazine/precursor flow rate ratio are from 1 to 80.
The inert dilution gas introduced on an optional basis into the reaction chamber can be an inert gas, for example, nitrogen or a rare gas such as argon.
Since neither the precursor nor the hydrazine used by this invention contains chlorine, their reaction does not generate the ammonium chloride by-product that has heretofore been a problem. Moreover, while the silylhydrazine and/or hydrazine used by this invention includes species that contain carbon, a relatively low carbon concentration in the silicon nitride product has been confirmed even for the use of such carbon-containing species.
The production of silicon nitride films by the use of silylhydrazine by itself and its thermal decomposition will now be considered. In this case, silylhydrazine gas is introduced into the reaction chamber, along with any inert dilution gas used on an optional basis, and a silicon nitride film is produced by thermal decomposition of the silylhydrazine. As in the CVD procedure considered above, the pressure in the reaction chamber can be maintained at from 0.1 torr to 1,000 torr, while the pressure in the reaction chamber is preferably maintained at from 0.1 torr to 10 torr.
As with the CVD procedure considered above, decomposition of the silylhydrazine gas can generally be carried out at temperatures from 300° C. to 1,000° C. This silylhydrazine decomposition can produce silicon nitride at sufficiently high growth rates (film formation rate) even at low temperatures of 400° C. to 700° C. In addition, high step coverage ratios can be achieved when the decomposition temperature is 300° C. to 500° C.
For both the CVD procedure and the thermal decomposition procedure, the silylhydrazine gas can be prepared in advance and stored in a sealed container until use or can be synthesized onsite and the gaseous reaction mixture containing the synthesized silylhydrazine gas can be introduced into the reaction chamber. A silylamine gas and a hydrazine gas are introduced into a synthesis chamber in order to effect this onsite synthesis of silylhydrazine gas. At this point, an inert dilution gas, such as the inert dilution gas that may be introduced into the reaction chamber as discussed above, can also be introduced into the synthesis chamber along with the aforementioned reaction gases. With regard to the conditions during introduction of the silylamine gas and hydrazine gas into the synthesis chamber, the pressure in the synthesis chamber should be maintained at 0.1 to 1,000 torr and the hydrazine gas/silylamine gas flow rate ratio should be 10 to 1,000. The two gases can be reacted at temperatures ranging from room temperature to 500° C. Silylhydrazine is produced by this reaction. The resulting silylhydrazine-containing gaseous reaction mixture within the synthesis chamber can then be subjected to pressure adjustment by a pressure regulator and introduced into the above-described reaction chamber. The silylamine used here encompasses silylamine defined by formula (III)
(H3Si)mN(H)3-m (III)
wherein m is an integer from 1 to 3. The hydrazine introduced into the synthesis chamber encompasses hydrazine defined by formula (IV)
H(Rx)N—N(Ry)Rz (IV)
wherein Rx, Ry, and Rz are each independently selected from the hydrogen atom, methyl, ethyl, and phenyl.
Silylhydrazine (I), for example, can be produced by the reaction of the silylamine (III) and hydrazine (IV).
The production apparatus 10 illustrated in
A susceptor 111 is disposed within the reaction chamber 11, and a semiconductor substrate 112, such as a silicon substrate, is mounted on the susceptor 111 (a single semiconductor substrate is mounted on the susceptor 111 since the apparatus illustrated in
The precursor gas source 12 comprises a sealed container that holds liquefied precursor. The precursor gas is introduced from its source 12 through the precursor gas feed line L1 and into the reaction chamber 11. There are disposed in this line L1 a shut-off valve V1 for the precursor gas source 12 and, downstream from said shut-off valve V1, a flow rate controller such as, for example, a mass flow controller MFC1. The precursor gas is subjected to control to a prescribed flow rate by the mass flow controller MFC1 and is introduced into the reaction chamber 11.
The hydrazine gas source 13 comprises a sealed container that holds liquefied hydrazine. The hydrazine gas is introduced from its source 13 through the hydrazine gas feed line L2 and into the reaction chamber 11. There are disposed in this line L2 a shut-off valve V2 and, downstream therefrom, a flow rate controller such as, for example, a mass flow controller MFC2. The hydrazine gas is subjected to control to a prescribed flow rate by the mass flow controller MFC2 and is introduced into the reaction chamber 11.
The inert dilution gas source 14 comprises a sealed container that holds the inert dilution gas. As necessary or desired, the inert dilution gas is introduced from its source 14 and into the reaction chamber 11 through the inert dilution gas feed line L3. As shown in
The outlet from the reaction chamber 11 is connected to a waste gas treatment facility 15 by the line L4. This waste gas treatment facility 15 removes, for example, the by-products and unreacted material, and the gas purified by the waste gas treatment facility 15 is discharged from the system. There are disposed in the line L4 a pressure sensor PG, a pressure regulator such as a butterfly valve BV1, and a vacuum pump PM. The introduction of each gas into the reaction chamber 11 is carried out by the respective mass flow controllers, while the pressure within the reaction chamber 11 is monitored by the pressure sensor PG and is established at a prescribed pressure value by operation of the pump PM and control of the aperture of the butterfly valve BV1.
When the silicon nitride film is to be produced by thermal decomposition of the silylhydrazine gas, use of the hydrazine feed system (the source 13, feed line L2, shut-off valve V2, and mass flow controller MFC2) becomes unnecessary and it need not be provided.
The production apparatus 20 illustrated in
The production apparatus 20 illustrated in
The hydrazine gas source 13 is provided with a feed line L22 to the synthesis chamber 21 in addition to the feed line L2 to the reaction chamber 11. There are disposed in this feed line L22 a shut-off valve V22 and, downstream therefrom, a flow rate controller such as, for example, a mass flow controller MFC22. The hydrazine gas is subjected to control to a prescribed flow rate by the mass flow controller MFC22 and is introduced into the synthesis chamber 21.
The inert dilution gas source 14 is provided with a feed line L23 to the synthesis chamber 21 in addition to the feed line L3 to the reaction chamber 11. There are disposed in this feed line L23 a shut-off valve V23 and, downstream therefrom, a flow rate controller such as, for example, a mass flow controller MFC23. As necessary or desired, the inert dilution gas is subjected to control to a prescribed flow rate by the mass flow controller MFC23 and is introduced into the synthesis chamber 21. The line L3 in the apparatus in
The outlet from the synthesis chamber 21 is connected by the line L24 to the reaction chamber 11. A pressure regulator, for example, a butterfly valve BV2, is provided in the line L24. The silylhydrazine gas-containing gaseous reaction mixture afforded by the synthesis chamber 21 is introduced into the reaction chamber 11 after the pressure in the synthesis chamber 21 has been adjusted by the butterfly valve BV2 as appropriate for introduction into the reaction chamber 11.
With regard to the handling of the precursor gas in the apparatus illustrated in
This invention will be described in additional detail by working examples as follows, but this invention is not limited to these working examples.
This example used a production apparatus with the structure illustrated in Example 1. Silicon nitride films were produced on silicon substrates at different CVD reaction temperatures (T) while introducing TSA gas at a feed flow rate of 0.5 sccm or 4 sccm and 1,1-dimethylhydrazine (UDMH) gas at a feed flow rate of 40 sccm into a reaction chamber that held a silicon substrate. The pressure within the reaction chamber was maintained at 1 torr. The silicon nitride deposition (growth) rate was measured during this process, and the obtained values are plotted logarithmically in
As may be understood from the results in
The composition of the obtained silicon nitride films as measured by Auger elemental analysis and ellipsometry was Si0.8-0.9N. The carbon content of the silicon nitride films prepared at a UDMH/TSA feed flow rate ratio of 80 was only 3 weight %. The etching rate of the individual silicon nitride films by 0.25% aqueous hydrogen fluoride was measured at 30-50 Å/min in all cases, which is substantially lower than the etching rate of silicon nitride films afforded by PECVD.
The gaseous reaction mixture within the reaction chamber was also analyzed by Fourier transform infrared spectroscopy (FTIR) in this example. It was confirmed at both UDMH/TSA feed flow rate ratios that (a) the intensity ratio (l(947)/l(2172)) for the two main peaks for TSA (the peak at about 947 cm−1 assigned to the SiN bond and the peak at about 2172 cm−1 assigned to the SiH bond) underwent a change (see
Using a production apparatus with the structure shown in
The results reported in
This invention has been described hereinabove through various embodiments and working examples, but this invention is not limited thereto. The various embodiments described above can be combined.
As has been described hereinabove, the inventive methods are not accompanied by the production of ammonium chloride, avoid significant admixture of carbonaceous contaminants in the film products, and also enable the production of silicon nitride films with better film properties even at relatively low temperatures.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/IB04/01346 | 4/8/2004 | WO | 10/17/2005 |