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TW201941300A - 形成氣隙的系統及方法 - Google Patents

形成氣隙的系統及方法 Download PDF

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TW201941300A
TW201941300A TW108105534A TW108105534A TW201941300A TW 201941300 A TW201941300 A TW 201941300A TW 108105534 A TW108105534 A TW 108105534A TW 108105534 A TW108105534 A TW 108105534A TW 201941300 A TW201941300 A TW 201941300A
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陳智君
徐霖
王安川
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美商應用材料股份有限公司
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Abstract

示例性蝕刻方法可包含將含氟前驅物流入半導體處理腔室之基板處理區域中。方法可包含將含氫前驅物流入基板處理區域中之步驟。方法可包含將容納在基板處理區域中的基板與含氟前驅物及含氫前驅物接觸之步驟。基板可包含溝槽或凹陷特徵，沿溝槽或特徵之側壁可形成間隔物。間隔物可包含複數個層，包含含碳或含氮材料之第一層、含氧材料之第二層以及含碳或含氮材料之第三層。間隔物之第二層可設置在間隔物之第一層與第三層之間。方法亦可包含移除含氧材料之步驟。

Description

形成氣隙的系統及方法
本技術關於半導體製程及設備。更具體而言，本技術關於選擇性地蝕刻高深寬比(high-aspect-ratio)結構。
藉由在基板表面上產生錯綜複雜圖案化的材料層的製程使積體電路成為可能。在基板上產生圖案化材料需要用於移除暴露的材料的受控方法。化學蝕刻用於各種目的，包含將光阻劑中的圖案轉移至下方的層中，將層薄化，或將已存在於表面上的特徵之橫向尺寸薄化。經常期望具有蝕刻一種材料比另一種材料更快的蝕刻製程，從而例如促使圖案轉移製程。上述蝕刻製程稱為對第一種材料具有選擇性。由於材料、電路系統及製程之多樣性，已開發出具有對各種材料的選擇性的蝕刻製程。
基於製程中使用的材料，蝕刻製程可稱為濕式或乾式。濕式HF蝕刻相對於其他介電質及材料優先移除氧化矽。然而，濕式製程可能難以穿透一些受限的溝槽，並且有時亦可能使剩餘材料變形。在基板處理區域內形成的局部電漿中產生的乾式蝕刻可穿透更多受限的溝槽並且展現出較少的精細剩餘結構之變形。然而，局部電漿可能在它們放電時經由電弧之產生而損傷基板。
因此，需要可用於生產高品質裝置及結構的改進的系統及方法。本技術解決了這些及其他需求。
示例性蝕刻方法可包含將含氟前驅物流入半導體處理腔室之基板處理區域中之步驟。方法可包含將含氫前驅物流入基板處理區域中之步驟。方法可包含將容納在基板處理區域中的基板與含氟前驅物及含氫前驅物接觸之步驟。基板可包含溝槽或凹陷特徵，沿溝槽或特徵之側壁可形成間隔物。間隔物可包含複數個層，包含含碳及/或含氮材料之第一層、含氧材料之第二層以及含碳及/或含氮材料之第三層。間隔物之第二層可設置在間隔物之第一層與第三層之間。方法亦可包含移除含氧材料之步驟。
在一些實施例中，含氫前驅物可與在半導體處理腔室之遠端電漿區域中的該半導體處理腔室內可形成的電漿維持流體隔離。含氫前驅物可為或包含水蒸氣。含氟前驅物可為或包含無水氟化氫(anhydrous hydrogen fluoride)。間隔物之每一層的特徵可在於深寬比大於或約為20:1。含氧材料的特徵可在於寬度小於或約為5 nm。蝕刻方法期間可將基板之溫度維持在低於或約為10°C。間隔物可進一步包含位於第二層與第三層之間的第四層。第四層可為含氧材料。間隔物之第四層的特徵可在於比間隔物之第二層化學計量較低的氧量。在蝕刻方法期間基板處理區域可維持無電漿(plasma free)。
本技術亦可涵蓋移除方法。方法可包含將含氟前驅物流入半導體處理腔室之基板處理區域中之步驟。方法可包含將水蒸氣流入基板處理區域中之步驟。方法可包含將容納在基板處理區域中的基板與含氟前驅物及水蒸氣接觸之步驟。基板可包含溝槽，沿溝槽之側壁可形成間隔物。間隔物可包含複數個橫向層，包含鄰近溝槽之側壁的含碳材料之第一層、包括含氧材料的第二層以及含碳材料之第三層。間隔物之第二層可設置在間隔物之第一層與間隔物之第三層之間。方法可包含維持半導體處理腔室之基板處理區域內的相對濕度低於或約為60%。方法可包含移除間隔物之第二層之步驟。
在一些實施例中，間隔物之第二層可為或包含鄰近間隔物之第一層的第一含氧層及鄰近間隔物之第三層的第二含氧層。第二含氧層的特徵可在於比第一含氧層低的氧含量。移除間隔物之第二層的步驟可包含以頂部至底部蝕刻的方式移除第一含氧層。移除間隔物之第二層的步驟亦可包含隨後以橫向蝕刻的方式移除第二含氧層。在第二層移除期間，可實質上維持間隔物之第一層及間隔物之第三層。可以相對於間隔物之第三層的大於或約為50:1的選擇性來移除間隔物之第二層。間隔物之第一層及間隔物之第三層可為或包含氮化矽或碳氮化矽。間隔物之第二層可在間隔物之第三層下方延伸。方法亦可包含從間隔物之第三層下方橫向蝕刻第二間隔物層之步驟。含氟前驅物可為無水氟化氫。在蝕刻方法期間基板處理區域可維持無電漿。
本技術亦可涵蓋蝕刻方法。方法可包含將無水氟化氫流入半導體處理腔室之基板處理區域中的步驟。方法可包含將水蒸氣流入基板處理區域中之步驟。方法亦包含將容納在基板處理區域中的基板與無水氟化氫及水蒸氣接觸之步驟。基板可包含溝槽，沿溝槽之側壁可形成間隔物。間隔物可包含複數個橫向層，包含鄰近溝槽之側壁的含碳材料之第一層、包括第一含氧材料及第二含氧材料的第二層及含氮材料之第三層，第二含氧材料與第一含氧材料不同。間隔物之第二層可設置在間隔物之第一層與間隔物之第三層之間。間隔物之第二層可至少部分地在間隔物之第三層下方橫向延伸。方法可包含維持半導體處理腔室之基板處理區域內的相對濕度低於或約為60%之步驟。方法亦可包含移除間隔物之第二層的步驟。
上述技術可提供優於習知系統及技術的眾多益處。例如，製程可允許蝕刻高深寬比特徵而不會腐蝕其他暴露的材料。另外，製程可允許在間隔物特徵內形成氣隙，其實質上維持其他暴露的材料。結合以下敘述及附圖更詳細地描述這些及其他實施例以及它們的許多優點及特徵。
稀釋的酸可用於許多不同的半導體製程中，用於清潔基板及從這些基板移除材料。例如，稀釋的氫氟酸可為氧化矽的有效蝕刻劑，並且可用於從矽表面移除氧化矽。在完成蝕刻或清潔操作之後，可從晶圓或基板表面將酸乾燥。使用稀釋的氫氟酸（「DHF」）可稱為「濕式」蝕刻，稀釋劑經常為水。可使用另外的蝕刻製程，其利用輸送至基板的前驅物。例如，電漿物質可與水蒸氣一起輸送至晶圓以形成蝕刻劑混合物。
儘管使用水溶液或基於水的製程的濕式蝕刻劑可有效地用於一些基板結構，但當在具有待移除的小間距特徵的基板上使用時，水可能造成問題。例如，氣隙形成製程可選擇性地移除基板上的薄材料層，其特徵可能在於幾奈米的厚度。因為濕式蝕刻劑之表面張力及其他特性，蝕刻劑可能不能穿透另外的層以穿過周圍結構蝕刻層。取決於氣隙之位置，特徵可在於高深寬比，從而進一步限制濕式蝕刻劑延伸穿過該特徵的能力。因此，許多習知技術不能在某些裝置配置中形成氣隙。
本技術藉由實行氣相蝕刻製程來克服這些問題，該製程允許穿過高深寬比特徵移除材料。在不同實施例中，該等製程可使用或可不使用電漿流出物(plasma effluent)作為蝕刻劑配方之一部分。本技術可能夠相對於含碳或含氮材料選擇性地蝕刻含氧材料。另外，基於某些實施例中的間隔物結構，蝕刻期間可保護暴露的含碳或含氮材料，蝕刻在習知另外的情況下為低選擇性蝕刻。在其中可能不形成電漿的實施例中，可使氧及羥基自由基的形成最小化，這可進一步保護周圍結構。
儘管其餘的揭示內容將常規地利用揭示的技術識別特定的蝕刻製程，但將容易理解的是，系統及方法同樣適用於所述的腔室中可能發生的沉積及清潔製程，以及包含後段製程(back-end-of-line)氣隙形成的其他蝕刻技術，及可用可維持或實質上維持的各種暴露材料實行的其他蝕刻。因此，本技術不應被視為限於僅與示例性蝕刻製程或腔室一起使用。此外，儘管描述了示例性腔室以對本技術提供基礎，但應理解，本技術可應用於可允許所述操作的幾乎任何半導體處理腔室。
第 1 圖 示出根據實施例的具有沉積、蝕刻、烘烤及固化腔室的處理系統100之一個實施例之俯視圖。在圖中，一對前開式晶圓傳送盒(FOUP) 102供應各種尺寸的基板，這些基板由機械臂104接收，並且在放入位於串聯部分109a~109c的基板處理腔室108a~108f中之一者之前放入低壓保持區域106中。第二機械臂110可用於將基板晶圓從保持區域106傳送至基板處理腔室108a~108f並且從基板處理腔室108a~108f返回保持區域106。處理腔室108a~108f中之每一者可經配備以實行多種基板處理操作，除了循環層沉積(CLD)、原子層沉積(ALD)、化學氣相沉積(CVD)、物理氣相沉積(PVD)、蝕刻、預清潔、脫氣、定向及其他基板製程之外，還包含本文所述的乾式蝕刻製程。
基板處理腔室108a~108f可包含一或更多個系統部件，用於在基板晶圓上沉積、退火、固化及/或蝕刻介電膜。在一種配置中，兩對處理腔室，例如，108c~108d及108e~108f，可用於在基板上沉積介電材料，並且第三對處理腔室，例如，108a~108b，可用於蝕刻沉積的介電質。在另一種配置中，所有三對腔室，例如，108a~108f，可經配置為蝕刻基板上的介電膜。所描述的製程中之任何一或更多者可在與不同實施例中所示的製造系統分開的一或更多個腔室中執行。將理解，系統100涵蓋用於介電膜的沉積、蝕刻、退火及固化腔室之另外的配置。
第 2A 圖 示出示例性製程腔室系統200之剖面圖，其中處理腔室內具有分隔的電漿產生區域。在膜蝕刻期間，例如，氮化鈦、氮化鉭、鎢、矽、多晶矽、氧化矽、氮化矽、氮氧化矽、碳氧化矽等，製程氣體可經由氣體入口組件205流入第一電漿區域215中。遠端電漿系統(RPS) 201可任選地包含在系統中，並且可處理第一氣體，隨後第一氣體行進經過氣體入口組件205。入口組件205可包含兩個或更多個不同的氣體供應通道，其中若包含第二通道（未示出），則可繞過(bypass) RPS 201。
冷卻板203、面板217、離子抑制器223、噴頭225及其上設置有基板255的基板支撐件265，根據實施例示出並且可各自包含於實施例中。基座265可具有熱交換通道，熱交換流體流過該熱交換通道以控制基板之溫度，熱交換流體可在處理操作期間被操作以加熱及/或冷卻基板或晶圓。基座265之晶圓支撐盤（其可包括鋁、陶瓷或其組合）亦可使用嵌入式電阻式加熱器元件電阻式加熱以便實現相對高的溫度，如從高達或約100°C至高於或約1100°C。
面板217可為金字塔形、圓錐形或另一種類似結構，其中窄的頂部擴展至寬的底部。如圖所示，面板217可另外為平坦的並且包含用於分配製程氣體的複數個貫穿通道。取決於RPS 201的使用，電漿產生氣體及/或電漿激發物質可穿過在面板217中的複數個孔洞，如第2B圖所示，用於更均勻地輸送至第一電漿區域215中。
示例性配置可包含使氣體入口組件205通向藉由面板217而從第一電漿區域215分隔的氣體供應區域258，使得氣體/物質流過面板217中的孔洞進入第一電漿區域215。可選擇結構性及操作性特徵以防止電漿從第一電漿區域215返回供應區域258、氣體入口組件205及流體供應系統210中的顯著回流。示出的面板217，或腔室之導電頂部分，以及噴頭225，具有位於特徵之間的絕緣環220，其允許AC電位相對於噴頭225及/或離子抑制器223施加至面板217。絕緣環220可位於面板217與噴頭225及/或離子抑制器223之間，使得能夠在第一電漿區域中形成電容式耦合電漿(CCP)。擋板（未示出）可另外位於第一電漿區域215中，或以其他方式與氣體入口組件205耦接，以影響經由氣體入口組件205進入區域中的流體之流動。
離子抑制器223可包括板或其他幾何形狀，其在整個結構中界定複數個孔，這些孔經配置以抑制離子帶電物質從第一電漿區域215遷移出，同時允許不帶電的中性或自由基物質穿過離子抑制器223進入抑制器與噴頭之間的活化氣體輸送區域中。在實施例中，離子抑制器223可包括具有各種孔配置的穿孔板。這些不帶電的物質可包含高反應性物質，其由較低反應性的載氣輸送而經過孔。如上所述，經由孔洞的離子物質之遷移可減少，並且在一些情況下可完全抑制。控制穿過離子抑制器223的離子物質之量可有利地提供對與下方的晶圓基板接觸的氣體混合物的增加的控制，進而可增加對氣體混合物之沉積及/或蝕刻特徵的控制。例如，調整氣體混合物的離子濃度可顯著改變其蝕刻選擇性，例如，SiNx:SiOx蝕刻比率、Si:SiOx蝕刻比率等。在實行沉積的替代實施例中，調整亦可改變用於介電材料的保形至可流動式沉積(conformal-to-flowable style deposition)的平衡。
離子抑制器223中的複數個孔可經配置以控制活化氣體（即，離子、自由基及/或中性物質）穿過離子抑制器223。例如，可控制孔洞之深寬比，或孔洞直徑與長度的關係，及/或孔洞之幾何形狀，使得穿過離子抑制器223的活化氣體中的離子帶電物質的流動減少。離子抑制器223中的孔洞可包含面向電漿激發區域215的逐漸變細(tapered)部分，以及面向噴頭225的圓柱形部分。圓柱形部分的形狀及尺寸可經設計以控制流至噴頭225的離子物質的流動。可調整的電偏壓亦可施加至離子抑制器223，作為控制離子物質流過抑制器的另外手段。
離子抑制器223可作用為減少或消除從電漿產生區域行進至基板的離子帶電物質之量。不帶電的中性及自由基物質仍可穿過離子抑制器中的開口以與基板反應。應注意，在實施例中，可不實行在環繞基板的反應區域中的離子帶電物質的完全消除。在某些情況下，離子物質欲抵達基板以便實行蝕刻及/或沉積製程。在這些情況下，離子抑制器可幫助將反應區域中離子物質之濃度控制在有助於製程的水平(level)。
噴頭225與離子抑制器223的組合可允許存在於第一電漿區域215中的電漿避免直接激發基板處理區域233中的氣體，同時仍允許激發物質從腔室電漿區域215行進至基板處理區域233中。如此一來，腔室可經配置以防止電漿接觸正被蝕刻的基板255。這可有利地保護在基板上圖案化的各種複雜結構及膜，其若直接與產生的電漿接觸則可能受損傷、錯位或以其他方式翹曲。另外，當允許電漿接觸基板或接近基板面時，氧化物物質蝕刻的速率可增加。因此，若材料之暴露區域為氧化物，則可藉由遠離基板維持電漿來進一步保護該材料。
處理系統可進一步包含電源240，電源240與處理腔室電耦合，以提供電功率至面板217、離子抑制器223、噴頭225及/或基座265，以在第一電漿區域215或處理區域233中產生電漿。電源可經配置以取決於所實行的製程輸送可調整的功率量至腔室。上述配置可允許可調諧電漿用於正在實行的製程中。與經常呈現為開啟或關閉功能的遠端電漿單元不同，可調諧電漿可經配置以輸送特定功率量至電漿區域215。這進一步可允許開發特定的電漿特性，使得前驅物可以特定方式解離以增強由這些前驅物產生的蝕刻輪廓。
電漿可在噴頭225上方的腔室電漿區域215或噴頭225下方的基板處理區域233中點燃。電漿可存在於腔室電漿區域215中，以從例如含氟前驅物或其他前驅物之流入產生自由基前驅物。通常在射頻(RF)範圍內的AC電壓可施加在處理腔室之導電頂部（如面板217）與噴頭225及/或離子抑制器223之間，以在沉積期間點燃腔室電漿區域215中的電漿。RF電源可產生13.56 MHz的高RF頻率，但亦可單獨產生其他頻率或與13.56 MHz頻率組合產生其他頻率。
第 2B 圖 示出影響經由面板217的處理氣體分配的特徵之詳細視圖253。如第2A圖及第2B圖所示，面板217、冷卻板203及氣體入口組件205相交以界定氣體供應區域258，製程氣體可從氣體入口205輸送至氣體供應區域258。氣體可填充氣體供應區域258並且經由面板217中的孔259流至第一電漿區域215。孔259可經配置以實質上單向的方式引導流動，使得製程氣體可流入處理區域233，但可部分地或完全地防止在穿越面板217之後回流至氣體供應區域258中。
用於處理腔室部分200的如噴頭225的氣體分配組件可稱為雙通道噴頭(dual channel showerhead; DCSH)，並且在第3圖所述的實施例中另外詳述。雙通道噴頭可提供蝕刻製程，其允許在處理區域233之外側分隔蝕刻劑，以在被輸送至處理區域之前提供與腔室部件及彼此的受限的相互作用。
噴頭225可包括上板214及下板216。板可彼此耦接以在該等板之間界定容積218。板之耦接可用以提供穿過上板及下板的第一流體通道219，以及穿過下板216的第二流體通道221。形成的通道可經配置以提供從容積218單獨經由第二流體通道221穿過下板216的流體出入口，並且第一流體通道219可與板與第二流體通道221之間的容積218流體隔離。容積218可經由氣體分配組件225之一側流體地出入。
第 3 圖 為根據實施例的與處理腔室一起使用的噴頭325之底視圖。噴頭325可對應於第2A圖所示的噴頭225。貫通孔365（示出第一流體通道219之視圖）可具有複數種形狀及配置，以便控制及影響經由噴頭225的前驅物之流動。小孔洞375（示出第二流體通道221之視圖）可在噴頭之表面上方實質上均勻地分佈，甚至在貫通孔365之間實質上均勻地分佈，並且可幫助在前驅物離開噴頭時提供比其他配置更均勻的前驅物混合。
先前論述的腔室可用於實行包含蝕刻方法的示例性方法。轉向第 4 圖 ，示出了根據本技術之實施例的方法400中的示例性操作。方法400可包含在方法啟動之前的一或更多個操作，包含前端處理、沉積、蝕刻、拋光、清潔或可在所述的操作之前實行的任何其他操作。方法可包含多個任選的操作，其可或可不與根據本技術的方法之一些實施例具體相關聯。例如，描述了許多操作以便提供更廣泛的結構形成之範圍，但該等操作對於該技術不是關鍵的，或可藉由替代方法來實行，如以下將進一步論述。方法400描述第 5A 圖 ~ 第 5D 圖 中示意性示出的操作，將結合方法400之操作描述第 5A 圖 ~ 第 5D 圖 之說明。應理解第5圖僅繪示部分示意圖，並且基板可含有具有如圖式中繪示的態樣的任何數量的結構部分，以及可仍然受益於本技術之操作的替代結構態樣。
方法400可涉及用以發展半導體結構的任選的操作至特定的製造操作。如第5A圖所繪示，半導體結構可表示裝置，其中已在基板501中形成溝槽、通孔(via)或其他凹陷特徵。如所繪示的，結構500可包含由矽或一些其他半導體基板材料以及層間介電材料製成或含有矽或一些其他半導體基板材料以及層間介電材料的基板501，在基板501上可形成凹槽、溝槽、通孔或隔離結構。溝槽503（亦可為通孔或本技術類似地涵蓋的其他凹槽）可包含形成在基板501之側壁502與形成或位在溝槽503內的材料504之間的間隔物505結構。材料504可為金屬材料、介電材料、接觸材料、電晶體材料或可用於半導體製程的任何其他材料。
間隔物505可包含彼此橫向相鄰形成的多個層。例如，如圖所繪示，間隔物505可包含第一層506、第二層508及第三層510。在不同的實施例中，間隔物505可包含任何數量的層，儘管在一些實施例中，間隔物可包含至少三層材料。一些形成氣隙的方法，如在本技術之一些實施例中，可包含在間隔物之其他層之間形成犧牲層。在隨後的移除期間，可移除犧牲層以在間隔物之維持層之間提供氣隙。在一些實施例中，間隔物505之第二層508可繪示待從基板移除的犧牲材料，以在間隔物505之第一層506與第三層510之間產生氣隙。
在一些實施例中，如所繪示，間隔物505之第一層506及間隔物505之第二層508可在第三層510下方延伸一定量。由於這些層在製造期間可彼此形成在另一層上方，所形成的最後一層（如第三層510）可安置或設置在間隔物505之其他層上方。如所繪示，間隔物505之第二層508可包含在第三層510下方橫向延伸的部分509。類似地，第一層506可包含在第二層508以及第三層510下方橫向延伸的部分507。在一些實施例中，可在蝕刻操作期間移除犧牲間隔物材料之橫向部分。
應理解，該繪示僅包含根據本技術之一些實施例的間隔物之示意圖，並且沒有按任何特定比例繪製，而是繪示為強調本技術所涵蓋的可能結構之某些特性。例如，在一些實施例中，每個層可形成為橫向上類似的厚度，或者任何單獨的層可比任何其他層更厚。根據本技術的間隔物的特徵可在於結構之任何深寬比或高寬比，儘管在一些實施例中，間隔物的特徵可在於較大的深寬比，這可能不允許在習知技術中進行充分的蝕刻。例如，在一些實施例中，間隔物之任何層之深寬比可大於或約為10:1、大於或約為20:1、大於或約為30:1、大於或約為40:1、大於或約為50:1或更大。另外，間隔物505之每層的特徵可在於減小的寬度小於或約為10 nm、小於或約為8 nm、小於或約為6 nm、小於或約為5 nm、小於或約為4 nm、小於或約為3 nm、小於或約為2 nm、小於或約為1 nm或更小，包含任何所述數字之任何分數，如2.5 nm、1.5 nm等。
高深寬比及最小寬度的這種組合可能阻礙許多習知的蝕刻操作，或需要實質上更長的蝕刻時間來移除層（如層508），其經由受限寬度的長垂直距離。在習知技術中，因為暴露於化學蝕刻劑的時間，間隔物層510在上述製程中可能更容易被蝕刻。例如，由於產生第二間隔物層508所實行的製程，第一間隔物層506的特徵可在於更高品質或更密集的結構。例如，第二間隔物層508之形成可在大於約50°C或大於約100°C的溫度下發生，例如，該溫度可提供第一間隔物層506之退火或緻密化之類型。第三間隔物層510可能不是如此，第三間隔物層510可在第二層508之形成後續形成。因此，當可垂直地移除犧牲層508，第一間隔物層506及第三間隔物層510之側壁可暴露於蝕刻劑。當第一間隔物層506之材料或品質可增強蝕刻劑相對於第一間隔物層506的選擇性，第三間隔物層510可在製程中被粗糙化或修整。在所有循環或在多個循環中蝕刻劑可與第三間隔物層510接觸的時間越長，可發生的移除越多。
因此，本技術之一些實施例可使用特定材料及製程來容納第三間隔物層510。例如，第5B圖繪示間隔物結構505，其中第二間隔物層508包含第一層508a及第二層508b。第二間隔物層508之第二層508b的特徵可在於與第一層508a不同的材料，如以下將進一步論述，第二層508b可用作第三間隔物層510上方的保護層。當第二間隔物層508包含多個層時，在實施例中，第二間隔物層508之全寬可仍小於或約為10 nm、小於或約為5 nm或小於或約為3 nm，其中第二間隔物層之每層貢獻與整體厚度相同或不同的量。
本技術涵蓋的材料可包含用於每個間隔物層的各種材料，如含矽材料。如前所述，當結構表示形成在基板上方的材料時，基板501可包含包括矽或多晶矽、矽鍺的材料，或其他材料，包含氧化矽或其他介電材料。儘管未繪示，但可在基板501之暴露的上表面上方形成一或更多個覆蓋材料，並且可包含氧化物及/或氮化物材料，或本文提到的任何其他材料。間隔物505的特徵可在於多個層，每個層可為任何數量的材料。例如，任何層可為或包含氧化矽、碳氧化矽、碳氮氧化矽、碳氮化矽或氮化矽。在一些實施例中，間隔物505之相鄰層可為不同的材料。例如，第二間隔物層508可為與第一間隔物層506及第三間隔物層510不同的材料，但第一間隔物層506可為與第三間隔物層510相同的材料。
在一些實施例中，第一間隔物層506及第三間隔物層510可為或包含含碳或含氮材料，如上述任何含氮化物材料，並且第二間隔物層508可為或包含含氧材料，如上述任何含氧材料。例如，一種可能的材料組合可包含用於第一間隔物層506的碳氮化矽，作為第二間隔物層508的氧化矽、碳氧化矽或碳氮氧化矽，以及作為第三間隔物層510的氮化矽。在包含多個犧牲層的實施例中，如第5B圖所繪示，第一層508a可為氧化矽，第二層508b可為含氧材料，其特徵在於與第一層508a不同的氧含量，如較低的氧含量或化學計量較低的氧量。如以下將解釋的，在實施例中，上述配置可有利地保護第三層510免受額外的蝕刻。
在實施例中，可實行方法400以移除第二間隔物層508或層508a、508b。該方法可包含在操作405將含氟前驅物流入半導體處理腔室之基板處理區域中的步驟。含氟前驅物可流過處理腔室之遠端電漿區域，如上述區域215，儘管在一些實施例中，方法400可不採用電漿流出物。例如，方法400可在不將前驅物暴露於電漿的情況下將含氟或其他含鹵素的前驅物流至基板。
在操作410，可將含氫前驅物流入基板處理區域中。含氫前驅物及含氟前驅物可共流入處理區域中，並且可流過處理腔室之不同或類似部分。例如，兩種前驅物可流過腔室之入口，或含氟前驅物可流過第一出入口進入腔室，並且含氫前驅物可流過第二出入口進入腔室。在操作415，含氟前驅物及含氫前驅物可接觸包含間隔物結構的半導體基板，如第5圖所繪示。在操作420，可移除第二間隔物508之至少一部分（其可為含氧材料），同時維持間隔物505之另外的層，如第一層506及第三層510。
該方法中使用的前驅物可包含含氟前驅物或含鹵素前驅物。示例性的含氟前驅物可為三氟化氮(NF3 )，其可流入遠端電漿區域中，該遠端電漿區域可與處理區域分開但與該處理區域流體耦合。其他氟源可與三氟化氮結合使用或作為三氟化氮的替代物使用。通常，可將含氟前驅物流入遠端電漿區域中，含氟前驅物可包含選自以下的群組的至少一種前驅物：原子氟、雙原子氟、三氟化氮、四氟化碳、氟化氫（包含無水氟化氫）、二氟化氙及用於半導體處理或可用於半導體處理中的各種其他含氟前驅物。前驅物亦可包含任何數量的載氣，其可包含氮氣、氦氣、氬氣或其他稀有、惰性或有用的前驅物。儘管可在製程中形成電漿，但在一些實施例中，含氟前驅物在被輸送至基板處理區域之前可能非電漿增強的或自由基化的，並且在一些實施例中，在示例性製程中可不形成電漿。
如本領域熟知技術者將理解的，含氫前驅物可包含氫、烴、水蒸氣、醇、過氧化氫或可包含氫的其他材料。輔助前驅物亦可包含另外的前驅物，如載氣或惰性材料。在一些實施例中，含氫前驅物（如水蒸氣）可維持與可在遠端電漿區域內形成的電漿流體隔離。在一些實施例中，在蝕刻方法期間不形成電漿，以幫助保護含碳或含氮材料，如環繞犧牲層的間隔物層。儘管電漿製程之選擇性可比氮化物材料更快地蝕刻氧化物材料，但因為上述高深寬比及相對薄的材料寬度，將第三間隔物層510之側壁暴露於包含水蒸氣的蝕刻劑可能導致在移除期間發生薄化，其可能無法維持第三間隔物層之足夠厚度。在實施例中，在移除操作期間，電漿處理區域可維持無電漿。無電漿意指在操作期間可能不在處理區域內主動地形成電漿，儘管在操作期間可使用如前所述遠端產生的電漿流出物。
與水蒸氣及含鹵素前驅物（可為含氟前驅物或其他鹵素）的反應製程可使含氟材料解離以形成蝕刻劑。氧化矽或其他含氧材料可接收質子，如氫，隨後可藉由蝕刻劑蝕刻該材料以產生揮發性成分及其他反應副產物。另外，一些習知技術可實行產生固體副產物的製程，固體副產物在連續蝕刻之前被移除，其可在蝕刻且隨後移除副產物的循環中來實行。對於高深寬比特徵，上述製程可能更耗時，這可能需要許多循環來完成蝕刻製程。本技術可能不會遭受這些缺陷，因為可能不形成固體副產物，並且蝕刻可能在與氧化物材料接觸時開始。例如，含氫前驅物（其可為水蒸氣）可在基板之表面上冷凝，並且可與含氟前驅物相互作用，含氟前驅物可解離並且開始蝕刻而沒有潛伏期(incubation)。因此，在一些實施例中，蝕刻操作可在單一循環中實行，儘管可實行多個蝕刻循環。另外，製程可在小於或約為30分鐘、小於或約為25分鐘、小於或約為20分鐘、小於或約為15分鐘、小於或約為10分鐘、小於或約為5分鐘或更短的時間內完全移除第二間隔物層508。
轉向第5C圖，第5C圖示出實施例，其中第二間隔物層508被部分移除以限制第三間隔物層510之減少。當第二間隔物508之第二層508b包含另外的碳或氮含量，或與第一層508a相比較低的氧含量時，第二層508b的特徵可在於比第一層508a更低的蝕刻速率。因此，在大量移除第二層508b之前（如少於50%的移除、少於或約60%的移除、少於或約70%的移除、少於或約80%的移除、少於或約90%的移除），或在將第三間隔物層510之側壁完全暴露之前，可實質上或完全地移除第一層508a。第二層508b的特徵可在於若僅從頂部向下方式進行蝕刻則為相對慢的蝕刻速率，並且此種情況可將第三間隔物層510暴露於蝕刻劑達足以損傷該層的時間。然而，藉由在第一間隔物層506與第二層508b之間形成間隙，蝕刻劑可填充孔隙並且完全暴露第二層508b。另外，因為隨後蝕刻可部分地、實質上或本質上橫向地實行，蝕刻之距離可小於或約為5 nm，這可大幅減少移除第二層508b的時間。
隨後可完全移除第二層508b，如第5D圖所繪示，同時實質上或本質上維持第三間隔物層510及第一間隔物層506。儘管取決於形成間隔物505之每個層的材料，可能發生間隔物層510之頂部處的部分圓化，但可發生間隔物層510之最小移除，並且該層可從初始形成量維持多於50%。在一些實施例中，第三間隔物層510可從初始形成量維持多於60%、從初始形成量維持多於70%、從初始形成量維持多於80%、從初始形成量維持多於90%、從初始形成量維持多於95%、從初始形成量維持多於97%、從初始形成量維持多於99%或更多。由本技術形成的氣隙可在第一間隔物層506與第三間隔物層510之間取決於定向延伸垂直長度或水平長度，以及延伸第三間隔物層510下方的完整橫向距離。
製程條件亦可影響在方法400中實行的操作以及根據本技術的其他移除方法。方法400之每個操作可在實施例中的恆定溫度期間實行，而在一些實施例中，可在不同操作期間調整溫度。例如，在實施例中，方法400期間的基板、基座或腔室溫度可維持在低於或約為50°C。基板溫度亦可維持在低於或約為45°C、低於或約為40°C、低於或約為35°C、低於或約為30°C、低於或約為25°C、低於或約為20°C、低於或約為15°C、低於或約為10°C、低於或約為5°C、低於或約為0°C、低於或約為-5°C或更低。溫度亦可維持在這些範圍內、由這些範圍所涵蓋的較小範圍內或介於這些範圍中之任一者之間的任何溫度下。
腔室內的壓力亦可影響所實行的操作，並且在實施例中，腔室壓力可維持在低於約50托、低於或約為40托、低於或約為30托、低於或約為25托、低於或約為20托、低於或約為15托、低於或約為10托、低於或約為5托、低於或約為1托或更低。壓力亦可維持在這些範圍內、由這些範圍所涵蓋的較小範圍內或介於這些範圍中之任一者之間的任何壓力下。藉由在低於約30托的壓力下實行操作，可增加製程之關於含碳或含氮材料的選擇性。
壓力亦可用於在蝕刻或移除操作期間維持特定的相對濕度。在一些實施例中，在整個蝕刻操作期間，處理腔室內的相對濕度可維持在低於約75%，這可促進改善含氧材料之移除。在其他實施例中，相對濕度可維持低於或約為50%、低於或約為45%、低於或約為40%、低於或約為35%、低於或約為30%、低於或約為25%、低於或約為20%、低於或約為15%、低於或約為10%或更低。相對濕度亦可維持在這些數字中之任一者之間，或在這些範圍內包含的任何較小範圍內。
亦可用任何其他處理條件來調整一或更多種前驅物之流速。例如，在移除操作期間，可減少、維持或增加含氟前驅物之流速。在方法400之任何操作期間，含氟前驅物之流速可在約5 sccm與約1000 sccm之間。另外，含氟前驅物之流速可為至少或約為10 sccm、至少或約為25 sccm、至少或約為50 sccm、至少或約為100 sccm、至少或約為150 sccm、至少或約為200 sccm、至少或約為250 sccm、至少或約為300 sccm、至少或約為400 sccm、至少或約為500 sccm、至少或約為700 sccm、至少或約為900 sccm或更多。流速亦可在這些所述流速中之任一者之間，或在這些數量中之任何所涵蓋的較小範圍內。
含氫前驅物可取決於使用的前驅物以這些流速中之任一者流動，其可為任何數量的含氫前驅物。例如，在使用水蒸氣的實施例中，可以至少或約為0.1 g/min的速率引入蒸氣。可以至少或約為0.2 g/min、至少或約為0.3 g/min、至少或約為0.4 g/min、至少或約為0.5 g/min、至少或約為0.6 g/min、至少或約為0.7 g/min、至少或約為0.8 g/min、至少或約為0.9 g/min、至少或約為1 g/min、至少或約為1.5 g/min或更大的速率引入水蒸氣，儘管可以低於約5 g/min或更低或約為1 g/min引入蒸氣，以減少或限制在部件及基板上的冷凝。水蒸氣亦可以介於這些所述的流速中之任一者之間或在這些數字所涵蓋的較小範圍內的流速引入。
本技術可相對於其他材料選擇性地蝕刻氧化矽、碳氧化矽、碳氮氧化矽或其他含氧材料，並且可相對於其他類型的氧化矽選擇性地蝕刻一些類型的氧化矽。例如，本技術可以至少約10:1的速率相對於熱氧化物蝕刻沉積的氧化矽，並且可以至少約15:1、至少約20:1、至少約50:1、至少約100:1或更大的速率相對於熱氧化物蝕刻沉積的氧化物。沉積的氧化物可包含旋塗介電質，或沉積技術，包含CVD、PECVD及其他沉積技術。本技術亦可相對於氮化矽、具有任何碳及氮比率的碳氮化矽膜、或碳氮氧化矽，以至少約20:1、至少約25:1、至少約30:1、至少約50:1、至少約100:1、至少約150:1、至少約200:1、至少約250:1、至少約300:1、至少約350:1、至少約400:1、至少約450:1、至少約500:1或更高的速率蝕刻任何含氧材料。
先前論述的方法可允許從基板移除氧化物材料以在兩層的含碳及/或含氮材料之間形成氣隙，同時維持含碳及/或含氮特徵之臨界尺寸（其可為高深寬比特徵），並且同時維持其他材料，包含金屬及含金屬材料，以及其他含矽材料。藉由採用本方法及操作，可蝕刻具有相對薄的初始暴露之寬度的高深寬比特徵，同時與濕式蝕刻不同並不會導致圖案坍塌，並且同時與一些習知乾式蝕刻不同不移除或本質上維持暴露的間隔物層。
在前面的敘述中，為了解釋的目的，已闡述眾多細節以便提供對本技術之各種實施例的理解。然而，對於本領域熟知技術者顯而易見的是，可在沒有這些細節中的一些細節或具有另外的細節的情況下實踐某些實施例。
已揭示了若干實施例，本領域熟知技術者將認知，在不脫離實施例之精神的情況下，可使用各種修改、替代構造及均等物。另外，沒有描述許多眾所周知的製程及元件，以避免不必要地使本技術模糊。因此，以上描述不應被視為限制本技術之範疇。另外，方法或製程可被描述為依序的或以步驟的，但應理解，操作可同時實行，或以不同於列出的順序實行。
當提供值之範圍時，應理解，除非上下文另有明確說明，亦具體揭示該範圍之上限與下限之間的每一中間值至下限之單位之最小分數。涵蓋在所述範圍中的任何所述值或未敘述的中間值與所述範圍中的任何其他所述或中間值之間的任何較窄範圍。這些較小範圍之上限與下限可獨立地包含在範圍中或排除在外，而包含上下限其中一者、兩者或不含上下限的較小範圍中的每一範圍亦涵蓋在本技術內，可具有所述範圍中特別排除的極限值。在所述範圍包含上下限之一或兩者的情況下，亦包含排除彼等所包含上下限中之一或兩者的範圍。
如本文及所附申請專利範圍中所使用，除非上下文另有明確說明，否則單數形式「一」、「一個」及「該」包含複數指稱。因此，例如，指稱「一前驅物」包含複數個上述前驅物，並且指稱「該層」包含指稱本領域熟知技術者已知的一或更多個層及其均等物等等。
此外，在本說明書及以下申請專利範圍中使用的詞語「包括」、「含有」、「包含」時，欲指明所述特徵、整體、部件、或操作的存在，但這些詞語不排除一或更多個其他特徵、整體、部件、操作、動作或群組的存在或附加。
100‧‧‧處理系統
102‧‧‧前開式晶圓傳送盒
104‧‧‧機械臂
106‧‧‧保持區域
108a‧‧‧基板處理腔室
108b‧‧‧基板處理腔室
108c‧‧‧基板處理腔室
108d‧‧‧基板處理腔室
108e‧‧‧基板處理腔室
108f‧‧‧基板處理腔室
109a‧‧‧串聯部分
109b‧‧‧串聯部分
109c‧‧‧串聯部分
110‧‧‧第二機械臂
200‧‧‧製程腔室系統/處理腔室部分
201‧‧‧遠端電漿系統/RPS
203‧‧‧冷卻板
205‧‧‧氣體入口組件
210‧‧‧流體供應系統
214‧‧‧上板
215‧‧‧第一電漿區域/電漿激發區域/腔室電漿區域
216‧‧‧下板
217‧‧‧面板
218‧‧‧容積
219‧‧‧第一流體通道
220‧‧‧絕緣環
221‧‧‧第二流體通道
223‧‧‧離子抑制器
225‧‧‧噴頭/氣體分配組件
233‧‧‧處理區域
240‧‧‧電源
253‧‧‧詳細視圖
255‧‧‧基板
258‧‧‧氣體供應區域
259‧‧‧孔
265‧‧‧基板支撐件/基座
325‧‧‧噴頭
365‧‧‧貫通孔
375‧‧‧小孔洞
400‧‧‧方法
405‧‧‧操作
410‧‧‧操作
415‧‧‧操作
420‧‧‧操作
500‧‧‧結構
501‧‧‧基板
502‧‧‧側壁
503‧‧‧溝槽
504‧‧‧材料
505‧‧‧間隔物
506‧‧‧第一層/第一間隔物層
507‧‧‧部分
508‧‧‧第二層/第二間隔物層
508a‧‧‧第一層
508b‧‧‧第二層
509‧‧‧部分
510‧‧‧第三層/第三間隔物層
藉由參照說明書之其餘部分及圖式，可實現對揭示的技術之本質及優點的進一步理解。
第1圖示出根據本技術之實施例的示例性處理系統之一個實施例之俯視圖。
第2A圖示出根據本技術之實施例的示例性處理腔室之示意剖面視圖。
第2B圖示出根據本技術之實施例的第2A圖中繪示的處理腔室之一部分之詳細視圖。
第3圖示出根據本技術之實施例的示例性噴頭(showerhead)之底視圖。
第4圖示出根據本技術之實施例的方法中的示例性操作。
第5A圖~第5D圖示出根據本技術之實施例的正在處理的基板之剖面視圖。
本文包含一些圖式作為示意圖。應理解，圖式是用於說明目的，除非特別說明按比例，否則不應視為按比例。另外，作為示意圖，提供圖式是幫助理解，並且可能不包含相較於現實表示的所有態樣或資訊，並且可能包含用於說明目的的附加或誇大的材料。
在附圖中，類似的部件及/或特徵可具有相同的參考標號。此外，可藉由在參考標號之後由區分相似部件的字母來區分相同類型的各種部件。若在說明書中僅使用第一參考標號，則描述適用於具有相同第一參考標號的任何一個類似部件，而與字母無關。
國內寄存資訊 (請依寄存機構、日期、號碼順序註記)
無
國外寄存資訊 (請依寄存國家、機構、日期、號碼順序註記)
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Claims (20)

  1. 一種蝕刻方法，包括以下步驟： 將一含氟前驅物流入一半導體處理腔室之一基板處理區域中；將一含氫前驅物流入該基板處理區域中；將容納在該基板處理區域中的一基板與該含氟前驅物及該含氫前驅物接觸，其中該基板包括一溝槽，其中沿該溝槽之一側壁形成一間隔物，其中該間隔物包含複數個層，該複數個層包含一含碳材料之一第一層、一含氧材料之一第二層以及一含碳材料之一第三層，及其中該間隔物之該第二層設置在該間隔物之該第一層與該第三層之間；及移除該含氧材料。
  2. 如請求項1所述之蝕刻方法，其中該含氫前驅物與在該半導體處理腔室之一遠端電漿區域中的該半導體處理腔室內可形成的一電漿維持流體隔離。
  3. 如請求項1所述之蝕刻方法，其中該含氫前驅物包括水蒸氣。
  4. 如請求項1所述之蝕刻方法，其中該含氟前驅物包括無水氟化氫。
  5. 如請求項1所述之蝕刻方法，其中該間隔物之每一層的特徵在於一深寬比大於或約為20:1。
  6. 如請求項5所述之蝕刻方法，其中該含氧材料的特徵在於一寬度小於或約為5 nm。
  7. 如請求項1所述之蝕刻方法，其中該蝕刻方法期間將該基板之一溫度維持在低於或約為10°C。
  8. 如請求項1所述之蝕刻方法，其中該間隔物進一步包括一第四層，該第四層位於該第二層與該第三層之間，並且其中該第四層為一含氧材料。
  9. 如請求項8所述之蝕刻方法，其中該間隔物之該第四層的特徵在於比該間隔物之該第二層一化學計量較低的氧量。
  10. 如請求項1所述之蝕刻方法，其中在該蝕刻方法期間該基板處理區域維持無電漿。
  11. 一種移除方法，包括以下步驟： 將一含氟前驅物流入一半導體處理腔室之一基板處理區域中； 將水蒸氣流入該基板處理區域中； 將容納在該基板處理區域中的一基板與該含氟前驅物及該水蒸氣接觸，其中該基板包括一溝槽，其中沿該溝槽之一側壁形成一間隔物，其中該間隔物包含複數個橫向層，該複數個橫向層包含鄰近該溝槽之一側壁的一含碳材料之一第一層、包括一含氧材料的一第二層以及一含碳材料之一第三層，及其中該間隔物之該第二層設置在該間隔物之該第一層與該間隔物之該第三層之間； 維持該半導體處理腔室之該基板處理區域內的一相對濕度低於或約為60%；及 移除該間隔物之該第二層。
  12. 如請求項11所述之移除方法，其中該間隔物之該第二層包括鄰近該間隔物之該第一層的一第一含氧層及鄰近該間隔物之該第三層的一第二含氧層。
  13. 如請求項12所述之移除方法，其中該第二含氧層的特徵在於比該第一含氧層低的一氧含量。
  14. 如請求項12所述之移除方法，其中移除該間隔物之該第二層包括以下步驟： 以一頂部至底部蝕刻的方式移除該第一含氧層；及 隨後以一橫向蝕刻的方式移除該第二含氧層。
  15. 如請求項14所述之移除方法，其中在該第二層移除期間，實質上維持該間隔物之該第一層及該間隔物之該第三層。
  16. 如請求項15所述之移除方法，其中以相對於該間隔物之該第三層的一選擇性來移除該間隔物之該第二層，該選擇性大於或約為50:1。
  17. 如請求項11所述之移除方法，其中該間隔物之該第一層及該間隔物之該第三層包括氮化矽或碳氮化矽。
  18. 如請求項11所述之移除方法，其中該間隔物之該第二層在該間隔物之該第三層下方延伸，及其中該方法進一步包括從該間隔物之該第三層下方橫向蝕刻該第二間隔物層。
  19. 如請求項11所述之移除方法，其中該含氟前驅物為無水氟化氫，及其中在該蝕刻方法期間該基板處理區域維持無電漿。
  20. 一種蝕刻方法，包括以下步驟： 將無水氟化氫流入一半導體處理腔室之一基板處理區域中； 將水蒸氣流入該基板處理區域中； 將容納在該基板處理區域中的一基板與該無水氟化氫及該水蒸氣接觸，其中該基板包括一溝槽，其中沿該溝槽之一側壁形成一間隔物，其中該間隔物包含複數個橫向層，該複數個橫向層包含鄰近該溝槽之一側壁的一含碳材料之一第一層、包括一第一含氧材料及一第二含氧材料的一第二層以及一含氮材料之一第三層，該第二含氧材料與該第一含氧材料不同，其中該間隔物之該第二層設置在該間隔物之該第一層與該間隔物之該第三層之間，及其中該間隔物之該第二層至少部分地在該間隔物之該第三層下方橫向延伸； 維持該半導體處理腔室之該基板處理區域內的一相對濕度低於或約為60%；及 移除該間隔物之該第二層。
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TWI766433B (zh) 2018-02-28 2022-06-01 美商應用材料股份有限公司 形成氣隙的系統及方法
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