This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2019-163301, filed on Sep. 6, 2019; the entire contents of which are incorporated herein by reference.
Embodiments of the present invention relate to a semiconductor device and a manufacturing method thereof.
A three-dimensional stacked semiconductor memory as an example of semiconductor devices has a stacked body in which conductive layers functioning as word lines and insulating layers are stacked in a three-dimensional manner. Ends of the stacked body are generally formed in a stepwise manner to be connected to contact plugs.
Embodiments will now be explained with reference to the accompanying drawings. The present invention is not limited to the embodiments.
A semiconductor device according to one embodiment includes a substrate, a stacked body including a plurality of conductive layers and a plurality of insulating layers alternately stacked on the substrate, and a plurality of first contact plugs individually connected to the conductive layers on an end of the stacked body. The semiconductor device includes, on the substrate, a lower layer three-dimensional structure including any of a lower layer inclined structure continuously inclined upward with respect to a flat surface of the substrate, a lower layer stepped structure inclined upward in a stepwise manner with respect to the flat surface, and a lower layer composite stepped structure in which planes parallel to the flat surface and slopes inclined upward with respect to the flat surface are alternately continuous. At least some of terrace regions being connection regions to the first contact plugs on top surfaces of the conductive layers are located on the lower layer three-dimensional structure.
The substrate 10 is, for example, a silicon substrate. A lower layer inclined structure 11 is formed on the substrate 10. In the present embodiment, the lower layer inclined structure 11 is an inclined surface continuously inclined upward with respect to a flat surface 12 of the substrate 10.
The stacked body 20 is located on the substrate 10. A plurality of conductive layers 21 and a plurality of insulating layers 22 are alternately stacked in the stacked body 20. Each of the conductive layers 21 functions as a word line. The conductive layers 21 are insulated from each other by the insulating layers 22. A terrace region 21a is formed at each end of the conductive layers 21. The terrace regions 21a are connection regions to the contact plugs 30 and are formed on the lower layer inclined structure 11 described above.
The contact plugs 30 are individually connected to the conductive layers 21 in the terrace regions 21a. The contact plugs 30 are insulated from each other by an upper layer insulating film 40.
A manufacturing method of the semiconductor device according to the present embodiment is explained below with reference to
First, the lower layer inclined structure 11 that is inclined at any inclination angle θ with respect to the flat surface 12 is formed on one surface of the substrate 10 as illustrated in
Next, a stacked body 20a is formed on the substrate 10 as illustrated in
Next, a mask material 50 is formed on the stacked body 20a as illustrated in
Subsequently, an opening 51 is formed on the mask material 50 as illustrated in
Next, the portion of the uppermost sacrifice layer 23 exposed from the opening 51 and a portion of the insulating layer 22 formed under the sacrifice layer 23 are removed, for example, by dry etching as illustrated in
Next, an end of the mask material 50 is slimmed as illustrated in
Lterrace=Lslim×cos θ (1)
Next, the portion of the uppermost sacrifice layer 23 and a portion of the insulating layer 22 formed under the uppermost sacrifice layer 23 are removed, for example, by dry etching as illustrated in
When slimming of the end of the mask material 50 and removal of the sacrifice layers 23 and the insulating layers 22 are thereafter repeated, the terrace regions 21a are formed on the lower layer inclined structure 11 as illustrated in
Next, the upper layer insulating film 40 is formed on the stacked body 20a as illustrated in
Next, the sacrifice layers 23 are replaced with the conductive layers 21 as illustrated in
Finally, the contact plugs 30 are formed to be connected to the conductive layers 21 in the terrace regions 21a, respectively, as illustrated in
In this comparative example, ends of the stacked body 120 are formed in a stepwise manner inclined downward in a stepwise manner from the uppermost layer to the lowermost layer. Accordingly, if the number of the stacked conductive layers 21 is large, a difference Δd in the depths between a contact plug 30a connected to the uppermost conductive layer 21 and a contact plug 30b connected to the lowermost conductive layer 21 is considerably large. In this case, overetching is likely to occur at the time of forming the contact plug 30a. At the time of forming the contact plug 30b, it is likely that the corresponding contact hole does not reach the lowermost conductive layer 21 and that a connection failure between the contact plug 30b and the conductive layer 21 occurs.
When the number of the conductive layers 21 is large, a depth dmax of the contact plug 30b is considerably large. In this case, problems such as increase in the electrical resistance, increase in the parasitic capacitance between contact plugs, and decrease in the productivity due to prolonged time of the etching process are concerned. Further, if a top diameter r of the contact plugs is enlarged to ensure the depth of the contact plug 30b, there is concern that the terrace regions 21a cannot be downscaled.
In contract thereto, according to the embodiment described above, the terrace regions 21a of the conductive layers 21 are formed on the lower layer inclined structure 11 of the substrate 10. Therefore, the difference Δd in the depths of the contact plugs 30 can be set to be equal to or smaller than half of the height of the stacked body 20. Since the depth dmax of the contact plug 30 connected to the lowermost conductive layer 21 is also reduced, technical problems such as a connection failure of the contact plugs 30, increase in the resistance, and increase in the parasitic capacitance can also be overcome.
Further, the productivity can be improved due to shortening of the processing time of etching. Since the top diameter r of the contact plugs 30 can be reduced, the chip area can be decreased by downscaling of the terrace regions 21a. Furthermore, the terrace regions 21a are formed using lithography and dry etching, so that misalignment of the connection regions of the contact plugs 30 can be prevented and the connection regions sufficient for connection can be formed.
In a semiconductor device 2 according to the present embodiment, the terrace regions 21a of the conductive layers 21 are formed not only on the lower layer inclined structure 11 formed on a substrate 10a but also on the flat surface 12 of the substrate 10a as illustrated in
In the present embodiment, the lower layer inclined structure 11 is formed on the surface of the substrate 10a being a silicon substrate using, for example, a crystal orientation anisotropic wet etching technique with an alkali aqueous solution. For example, an etchant such as potassium hydroxide, tetramethylammonium hydroxide (TMAH), or ethylenediamine pyrocatechol (EDP) is used as the alkali aqueous solution. This enables the lower layer inclined structure 11 composed of a (111) plane (facet) of silicon crystal to be formed.
In the lower layer inclined structure 11 formed by the anisotropic wet etching, the inclination angle θ is about 55° and steep. Therefore, in a case in which all the terrace regions 21a cannot be formed on the lower layer inclined structure 11, the terrace regions 21a formed in a stair-like fashion are combined. In this case, the terrace regions 21a of a predetermined number of conductive layers 21 including the lowermost conductive layer 21 are formed on the lower layer inclined structure 11. Accordingly, as compared to the semiconductor device 100 according to the comparative example described above, the difference Δd in the depths of the contact plugs 30 can be reduced and the depth dmax of the contact plug 30 connected to the lowermost conductive layer 21 can also be decreased.
In the present embodiment, the lower layer inclined structure 11 is formed by wet etching. Therefore, the lower layer inclined structure 11 can be formed at lower cost than in the first embodiment in which dry etching is used.
In a semiconductor device 3 according to the present embodiment, the top surface of a substrate 10b is entirely a flat surface as illustrated in
The lower layer insulating film 60 can be formed, for example, as a silicon dioxide film on the substrate 10b being a silicon substrate. The lower layer inclined structure 61 can be formed by a wet etching process using a resist. At this time, the adhesion between the surface of the lower layer insulating film 60 and the resist is controlled to enable formation of the lower layer inclined structure 61 with any inclination angle θ. The adhesion between the surface of the lower layer insulating film 60 and the resist can be controlled by changing the film property of the lower layer insulating film 60 or the resist, or the surface state of the lower layer insulating film 60.
According to the present embodiment explained above, similarly in the first embodiment, the difference Δd in the depths of the contact plugs 30 can be reduced and the depth of the contact plug 30 connected to the lowermost conductive layer 21 can also be decreased as compared to the semiconductor device 100 according to the comparative example.
In the present embodiment, because the lower layer inclined structure 61 is formed by wet etching, the lower layer inclined structure 61 can be formed at lower cost than in the first embodiment in which dry etching is used.
In a semiconductor device 4 according to the present embodiment, a lower layer stepped structure 13 is formed on the surface of a substrate 10c as illustrated in
The lower layer stepped structure 13 can be formed, for example, by dry etching the surface of the substrate 10c. A plurality of terrace regions 21a are formed in a stepwise manner on each step of the lower layer stepped structure 13.
According to the present embodiment explained above, similarly in the first embodiment, the difference Δd in the depths of the contact plugs 30 can be reduced and the depth of the contact plug 30 connected to the lowermost conductive layer 21 can also be decreased as compared to the semiconductor device 100 according to the comparative example. Further, in the present embodiment, the lower layer inclined structure 11 does not need to be formed and it is easy to stably form a lower layer three-dimensional structure.
In a semiconductor device 5 according to the present embodiment, a lower layer composite stepped structure 14 is formed on the surface of a substrate 10d. In the lower layer composite stepped structure 14, planes 14a parallel to the flat surface 12 and slopes 14b inclined upward with respect to the flat surface 12 are alternately continuous.
The lower layer composite stepped structure 14 can be formed, for example, by a combination of dry etching and crystal orientation anisotropic wet etching with an alkali aqueous solution. The terrace regions 21a are formed on the lower layer composite stepped structure 14.
According to the present embodiment explained above, similarly in the first embodiment, the difference Δd in the depths of the contact plugs 30 can be reduced and the depth of the contact plug 30 connected to the lowermost conductive layer 21 can also be decreased as compared to the semiconductor device 100 according to the comparative example.
Further, in the present embodiment, a combination of plane structures and slope structures eliminates the need of causing the inclined surface to be gentler and it is easy to stably form a lower layer three-dimensional structure.
In a semiconductor device 6 according to the present embodiment, a concave portion is formed on a substrate 10e as illustrated in
Although not illustrated in
A memory cell region R2 is formed in a central part of the concave portion. A plurality of memory films 70 are formed in the memory cell region R2. Although not illustrated in
The semiconductor device 6 according to the present embodiment also includes CMOS (Complementary Metal Oxide Semiconductor) circuit regions R3 on an outer side of the end regions R1. MOS transistors 71 for driving the memory films 70 are formed in the CMOS circuit regions R3. The MOS transistors 71 are connected to contact plugs 32 (third contact plugs). Top parts of the contact plugs 32 are also coplanar with the top parts of the contact plugs 30. The MOS transistors 71 and the contact plugs 32 are also provided in the semiconductor devices according to the embodiments described above and the comparative example.
The semiconductor device 6 according to the present embodiment is formed by forming the stacked body 20 and the memory films 70 according to any of the first embodiment, the second embodiment, the fourth embodiment, and the fifth embodiment, thereafter processing holes by dry etching for at least either the contact plugs 31 or the contact plugs 32 at the same time as the contact plugs 30, and simultaneously filling metallic films in the holes.
Since the depths are greatly different between the contact plug 30a connected to the uppermost conductive layer 21 and the contact plug 30b connected to the lowermost conductive layer 21 in the semiconductor device 100 according to the comparative example, it is difficult to fill metallic films in the holes and form the contact plugs 30a and 30b at the same time.
On the other hand, according to the present embodiment, the differences in the depth of the contact plugs 30 to 32 can be reduced and therefore the contact plugs can be formed at the same time. Accordingly, the process time can be shortened and the manufacturing cost can be reduced.
The memory films 70 are formed in a central part of a concave portion formed of the substrate 10f and the lower layer insulating film 60. Other parts of the structure are identical to those of the sixth embodiment.
The semiconductor device 7 according to the present embodiment is formed, for example, by forming the stacked body 20 and the lower layer insulating film 60 similarly in the third embodiment, and thereafter forming the contact plugs 31 by dry etching at the same time as the contact plugs 30.
In the present embodiment explained above, the difference in the depths between the contact plugs 30 connected to the conductive layers 21 and the contact plugs 31 connected to the memory films 70 can be reduced. Since this enables these contact plugs to be formed at the same time, the process time can be shortened and the manufacturing cost can be reduced.
In a semiconductor device 7a according to the present modification, while the stacked body 20, the lower layer insulating film 60, and the metal films 70 are formed on the substrate 10f, the MOS transistors 71 are formed on a substrate 10g. The MOS transistors 71 and the memory films 70 are connected to each other via metallic wiring layers 81 joined on a bonding surface 80.
According to the present modification explained above, the MOS transistors 71 are formed on a substrate different from a substrate on which the memory films 70 are formed, which can improve the integration of memory cells.
Next, the shape of the lower layer inclined structure 61 is measured (Step S12). At Step S12, for example, as illustrated in
Next, as explained in the first embodiment, the stacked body 20a including the insulating layers 22 and the sacrifice layers 23 alternately stacked is formed (Step S13), and the mask material 50 is subsequently formed (Step S14). Next, the opening 51 is formed on the mask material 50. Subsequently, a portion of an uppermost sacrifice layer 23 and a portion of an insulating layer 22 formed thereunder are removed by dry etching. Subsequently, slimming of the end of the mask material 50 and removal of a sacrifice layer 23 and an insulating layer 22 are repeated, thereby forming terrace regions in the sacrifice layers 23.
Lterrace=Lslim×cos θ (2)
At this time, in a case in which there is a difference between the desired inclination angle θ and an actually formed inclination angle θ2 as illustrated in
In order to solve this problem, a slimming length Lslim2 to form the desired terrace length Lterrace is calculated based on the measured inclination angle θ2 (Step S15), and the terrace regions are formed (Step S16) in the present embodiment.
As illustrated in
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
Number | Date | Country | Kind |
---|---|---|---|
JP2019-163301 | Sep 2019 | JP | national |
Number | Name | Date | Kind |
---|---|---|---|
7847334 | Katsumata et al. | Dec 2010 | B2 |
7952136 | Kito et al. | May 2011 | B2 |
8284601 | Son et al. | Oct 2012 | B2 |
8363481 | Kidoh et al. | Jan 2013 | B2 |
20090001419 | Han et al. | Jan 2009 | A1 |
20140061776 | Kwon | Mar 2014 | A1 |
20150076579 | Tsuji et al. | Mar 2015 | A1 |
20180226424 | Shin | Aug 2018 | A1 |
20200357801 | Chen | Nov 2020 | A1 |
Number | Date | Country |
---|---|---|
2008-192857 | Aug 2008 | JP |
2008-244485 | Oct 2008 | JP |
2011-49561 | Mar 2011 | JP |
4691124 | Jun 2011 | JP |
5100080 | Dec 2012 | JP |
2015-56642 | Mar 2015 | JP |
6092277 | Mar 2017 | JP |
Number | Date | Country | |
---|---|---|---|
20210074643 A1 | Mar 2021 | US |