The invention relates to non-volatile memory arrays and, in particular, to a compact architectural arrangement for fabrication of non-volatile memory devices and a method of making same.
A non-volatile memory device is both electrically erasable and programmable. Such a device retains data even after power to the device is terminated. One particular type of non-volatile memory device is an electrically erasable programmable read only memory (EEPROM) device. In an EEPROM device, programming and erasing are accomplished by transferring electrons to and from a floating gate electrode through a thin dielectric layer, known as a tunnel-oxide layer, located between the floating gate electrode and an underlying substrate. Typically, electron transfer is carried out by either hot electron injection or by Fowler-Nordheim tunneling. In either electron transfer mechanism, a voltage is coupled to the floating gate electrode by a control gate electrode, also known as a programming region. The control gate electrode or programming region is capacitively coupled to the floating gate electrode such that a voltage applied to the programming region is coupled to the floating gate electrode.
A traditional EEPROM device utilizes the floating gate, in a field effect transistor structure, positioned over but insulated from a channel region in the semiconductor substrate, and between source and drain regions. A threshold voltage characteristic of the transistor is controlled by an amount of charge that is retained on the floating gate. Thus, a minimum amount of voltage (i.e., the threshold voltage) must be applied to the control gate before the transistor is turned “on” to permit conduction between source and drain regions of the transistor is controlled by the amount of charge on the floating gate. A memory transistor is programmed to one of two states by accelerating electrons from the substrate channel region, through a thin dielectric tunnel layer and onto the floating gate.
A state of the memory transistor is read by placing an operating voltage across the source and drain with an additional voltage on the control gate of the memory transistor. A level of current flowing between the source and drain is detected to determine whether the device is programmed to be “on” or “off” for a given control gate voltage. A specific single memory transistor cell in a two-dimensional array of EEPROM memory cells is addressed for reading by (1) applying a source-drain voltage to source and drain lines in a column containing the cell being addressed, and; (2) applying a control gate voltage to the control gates in a row containing the cell being addressed.
As discussed, EEPROM memory cells may be erased electrically. One way in which the cell is erased electrically is by transfer of charge from the floating gate to the transistor drain through thin tunnel dielectric layer. Charge transfer is again accomplished by applying appropriate voltages to the source, drain, and control gate of the floating gate transistor. An array of EEPROM cells is generally referred to as a Flash EEPROM array because an entire array of cells, or a significant group of cells, is erased simultaneously.
As Flash EEPROM arrays become increasingly larger in terms of storage capacity, the semiconductor industry has attempted various ways of reducing a size of individual memory cells, and thus, reducing a size of the entire array. The size reduction however cannot impact reliability of the memory device.
The present invention is a method, and resulting device, for fabricating memory cells with extremely small geometrical features. The small area requirement is met due primarily to two significant factors. First, a judicious use of spacers, described in detail herein, allows a control gate/wordline. Select line, or other structure to be fabricated in extremely close proximity to, for example, an associated plurality of floating gates. Additionally, each of the plurality of floating gates is supplied with carriers (i.e., electrons or holes) through a plurality of charge injectors. Each of the plurality of charge injector regions is made by doping a localized area (e.g., through injector ion implantation), thereby creating a subsurface highly-doped region that receives bias from a nearby contact for charge generation, i.e., a tunneling injector.
In one exemplary embodiment, the present invention is a method of fabricating an electronic integrated circuit device on a first surface of a substrate (e.g., a silicon wafer). The method includes forming a semiconducting film layer on the substrate. In the case of a silicon wafer, a first dielectric layer, such as silicon dioxide, is first formed (e.g., thermally or deposited). An additional dielectric film layer is then formed over the semiconducting film layer. An aperture is created and spacers are formed on sidewalls of the aperture. The spacers are produced such that a distance between spacers on opposing sidewalls of the aperture is less than a limit of optical photolithography. An injector dopant region is then formed within the aperture created by the spacers. The semiconducting film layer underlying the second aperture is etched, thus forming a floating gate and a wordline.
The present invention is also a device produced using methods detailed herein. The device, in one exemplary embodiment, is a memory cell array that includes a plurality of floating gates forming a portion of a memory transistor. The plurality of floating gates are comprised substantially of a first semiconducting material, for example, polysilicon, and are constructed over a substrate with a gate dielectric material interposed between the plurality of floating gates and the substrate. A combination control gate/wordline is fabricated in close proximity to the plurality of floating gates with the wordline arranged such that a distance between a long axis of the wordline and a nearest portion of any of the plurality of floating gates is less than a limit of resolution of optical photolithography. An injector dopant region is disposed in close relationship to each of the plurality of floating gates.
With reference to
A cross-section A-A of
In a specific exemplary embodiment, the substrate 101 is a p-type silicon wafer (or alternatively, a p-type well in a substrate). The first dielectric layer 103A is a silicon dioxide layer and is approximately 100 Å to 250 Å in thickness. The first dielectric layer 103A may be formed by a thermal oxidation technique or alternatively may be deposited by any of a variety of techniques such as atomic layer deposition (ALD), chemical vapor deposition (CVD), low-pressure CVD (LPCVD), plasma-enhanced CVD (PECVD), or plasma-assisted CVD (PACVD). In this specific exemplary embodiment, the semiconductor layer 105A is a polysilicon layer 500 Å to 1500 Å in thickness, while the second dielectric layer 107A and third dielectric layer 109A are substantially comprised of silicon dioxide and silicon nitride, respectively. The third dielectric layer 109A is approximately 60 Å to 100 Å in thickness while a thickness of the second dielectric layer 107A may be changed to accommodate a preferred “width” of eventual spacers to be formed, described infra.
The plan view of
In cross-section B-B of
In
A “width” of the spacer is dependent upon both a thickness of the deposited spacer layer and a step-height over which the deposited spacer layer is deposited. Since the spacer forms next to a given feature, the spacer is self-aligned with the feature and underlying features. Further, the spacer allows an etch or alignment step surrounding the given feature to be below a photolithographic limit of resolution since the etch or alignment is now based merely on a combined thickness, “t,” of the etched second dielectric layer 107B and the etched third dielectric layer 109B (i.e., a step-height of a proximate structure formed by these dielectric layers).
This spacer etch step is exemplified with reference to both the plan views (i.e., “Option A” and “Option B”) and the cross-sectional view C-C of
Generally, typical photolithographic techniques are limited by physical constraints of the photolithographic system involving actinic radiation wavelength, λ, and geometrical configurations of the projection system optics. According to Rayleigh's criterion,
where NA is the numerical aperture of the optical system and is defined as NA=n sin α, where n is the index of refraction of the medium which the radiation traverses (usually air for this application, so n≅1) and α is a half-angle of divergence of the actinic radiation. For example, using deep ultraviolet (DUV) illumination with λ=193 nm, and NA=0.7, the lower limit of resolution is 168 nanometers (1680 Å). Techniques such as phase-shifted masks can extend this limit downward, but photomasks required employing this technique are extremely expensive and alignment errors may still be significant. The expense becomes greatly compounded with a realization that an advanced semiconductor process may employ more than 25 photomasks.
A “width” of the dielectric spacer 113B is dependent upon a thickness of the deposited spacer layer and a step height of proximate structures near where the spacer dielectric layer 113A is formed. The dielectric spacer 113B width is approximately 0.7·tspacer, where “tspacer” is the thickness of the dielectric spacer layer 113A, noted with reference to
The plan views of
S=0.18 μm −[2·{0.7(0.10 μm)}]
S=0.04 μm
Thus, the aperture in
With reference to
A cross-section E-E of
With reference to cross-section F-F of
Each of the plurality of injector regions 303 is made by doping a localized area (e.g., through injector ion implantation) creating a subsurface highly-doped region for receiving bias from a nearby contact for charge generation, i.e., a tunneling injector. A control gate is formed from a nearby polysilicon stripe acting as the control gate/wordline 203. In a specific exemplary embodiment where the control gate/wordline 203 and the floating gates 2051, 2052 are fabricated from polysilicon, a separation of the polysilicon stripe (i.e., the control gate/wordline 203) from the polysilicon-polysilicon floating gates 2051, 2052 can be minimized by utilizing the spacer methods outlined supra with reference to
The tunneling injector regions 303 are made in a manner similar to that described supra with respect to the injector dopant region 115 (
The tunneling injector creates space charge flowing toward the bottom of the substrate 101 below the STI dielectric fill regions 307. Due to a proximity of the tunneling injector to the memory transistor, one or more of the electrodes of the memory transistor is biased to attract charge, e.g., holes. An impact caused by the holes upon the charged electrode gives rise to secondary charge carriers, such as electrons, by impact ionization. Impact ionization imparts sufficient energy on the secondary charge carriers for tunneling into one of the floating gates 2051, 2052. Current stimulation in the injector (essentially a fast diode), and controlled electrode bias in the transistor leads to placement of precise amounts of charge on one of the floating gates 2051, 2052. Mechanisms of charge injection into the gate oxide 207 and the floating gates 2051, 2052 (or from the floating gates 2051, 2052 into the gate oxide 207) and substrate 101 include: photo-emission, Fowler-Nordheim tunneling, or Zener or avalanche breakdown (assuming carriers in the substrate 101 acquire energies in excess of electron or hole barrier heights).
Additionally, conventional source and drain dopant regions are not required in the tunneling injector regions 303. A sufficient availability of majority carriers such as electrons or holes will be provided from the tunneling injector regions 303 and injected or tunneled into the appropriate floating gate 2051, 2052.
With reference to a plan view of
In the foregoing specification, the present invention has been described with reference to specific embodiments thereof. It will, however, be evident to a skilled artisan that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. For example, skilled artisans will appreciate that other types of semiconducting and insulating materials other than those listed may be employed. Additional particular process fabrication and deposition techniques, such as low pressure chemical vapor deposition (LPCVD), ultra-high vacuum CVD (UHCVD), and low pressure tetra-ethoxysilane (LPTEOS) may be readily employed for various layers and still be within the scope of the present invention. Although the exemplary embodiments describe particular types of dielectric and semiconductor materials, one skilled in the art will realize that other types of materials and arrangements of materials may also be effectively utilized and achieve the same or similar advantages. Also, the substrate itself may be comprised of a non-semiconducting material, for example, a quartz reticle with a deposited and doped polysilicon layer. Additionally, although the exemplary embodiments are described in terms of an EEPROM memory cell integrated circuit device, a person of ordinary skill in the art will recognize that other integrated circuit devices may readily benefit from the fabrication process described herein as well. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.