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[0001] The present invention relates to the fabrication of integrated circuits. More particularly, the present invention relates to the formation of conductive material within an opening, e.g., a container such as used in the formation of container-type capacitors, a contact hole, etc.
[0002] In the fabrication of integrated circuits, various layers, e.g., conductive layers and insulative layers, are used. For example, during the formation of semiconductor devices, such as dynamic random access memories (DRAMs), insulating layers are used to electrically separate conductive layers such as doped polycrystalline silicon, aluminum, metal silicides, etc. It is often required that the conductive layers be interconnected through holes or openings in the insulating layer. Such holes are commonly referred to as contact holes, e.g., when the hole extends through an insulating layer to an active device area, or vias, e.g., when the hole extends through an insulating layer between two conductive layers. The profile of an opening is of particular importance such that specific characteristics can be achieved when a contact hole or via is provided or filled with one or more conductive materials, e.g., conductive barrier layers.
[0003] Conductive materials are also formed in openings when providing certain storage cell capacitors for use in semiconductor devices, e.g., DRAMs. Storage capacity and size are important characteristics of a storage cell. Generally, a storage cell capacitor is formed with a dielectric constant material interposed between two conductive electrodes. One or more layers of various conductive materials may be used as the electrode material. For example, one or more Group VIII metals, such as rhodium or platinum, may be used for the electrode material.
[0004] Many storage cell capacitors are formed by processes including high aspect ratio openings. For example, container-type capacitors are described in U.S. Pat. No. 5,392,189 to Fazan, et al., entitled “Capacitor Compatible With High Dielectric Constant Materials Having Two Independent Insulative Layers and the Method for Forming Same,” issued Feb. 21, 1995, and also in U.S. Pat. No. 5,270,241 to Dennison, et al., entitled “Optimized Container Stacked Capacitor DRAM Cell Utilizing Sacrificial Oxide Deposition and Chemical Mechanical Polishing,” issued Dec. 14, 1993. In such references, methods for forming container-type cell capacitor structures are described which generally include the formation of an insulative layer over existing topography and then etching openings into the insulative layer allowing access to the underlying topography, e.g., for a cell capacitor, the underlying topography may include conductive regions (e.g., conductive plugs). Thereafter, a conductive layer (e.g., polysilicon) to be used for forming the bottom electrode of the cell capacitor is formed within the openings, e.g., on the bottom surface and side walls of the openings, and is also formed on the upper surface of the insulative layer in which the opening has been defined. In one illustrative process described in the references, a layer of oxide material is formed over the polysilicon to a thickness enough to completely fill the polysilicon-lined openings. Thereafter, this oxide material is removed down to the polysilicon, preferably by chemical mechanical planarization (CMP) which selectively stops on the upper exposed regions of the polysilicon. Thereafter, the upper portions of the polysilicon are removed to separate neighboring polysilicon structures, thereby forming individual containers (e.g., contact openings lined with the polysilicon and filled with oxide material) and exposed insulative material between such containers. Thereafter, the oxide material still filling the opening over the polysilicon is removed, leaving the opening lined with a polysilicon bottom electrode for use in forming the container-type cell capacitor.
[0005] Storage capacity and size are important characteristics in a storage cell. One way to retain the storage capacity of a device and decrease its size is to increase the dielectric constant of the dielectric layer of the storage cell capacitor. Therefore, preferably a high dielectric constant material is used in applications interposed between two electrodes. Group VIII metals such as platinum, rhodium, iridium, ruthenium, and osmium, also sometimes referred to as noble metals, are desirable electrode materials for such high dielectric constant capacitors. Therefore, it is desirable to form the Group VIII metals or their alloys in openings as described above.
[0006] However, Group VIII metals, such as platinum or platinum alloys such as platinum-rhodium, are not easily planarized. For example, an illustrative planarization problem associated with the use of a Group VIII metal is shown in
[0007] As shown in
[0008] As described above, planarization problems are clearly apparent in the formation of Group VIII metal layers within openings, e.g., formation of bottom electrodes of container-type cell capacitor structures. Such problems are also applicable when forming conductive layers within openings for other applications, e.g., contact applications, via structures, etc.
[0009] To overcome the problems described above, e.g., those related to the planarization of Group VIII metals, various methods and structures are provided in the detailed description below. Many of the methods use support layers to assist in the planarization process or use a Group VIII metal material as an etch stop or end point for the planarization process with a subsequent etching step to remove unwanted portions of the Group VIII metal material formed in the various processes.
[0010] A method of providing a conductive material in an opening according to the present invention includes providing a substrate assembly having at least one surface and providing an opening defined through the surface of the substrate assembly. The opening is defined by at least one surface. At least one conductive material (e.g., at least one Group VIII metal such platinum and rhodium) is formed within the opening on the at least one surface defining the opening and on at least a portion of the substrate assembly surface. A support film (e.g., an oxide material) is formed over the conductive material and a fill material (e.g., a resist material) is formed over at least a portion of the support film. The fill material at least fills the opening. Thereafter, at least the fill material outside of the opening is removed by planarization. The support film outside of the opening, the at least one conductive material outside of the opening, the fill material within the opening, and the support film within the opening are then removed.
[0011] In one embodiment of the method, the support film outside of the opening and the conductive material outside of the opening are also removed to at least the surface of the substrate assembly by planarization.
[0012] In another embodiment of the method, the support film outside of the opening is also removed by planarization and the conductive material outside of the opening is removed to at least the surface of the substrate assembly by wet etching and/or dry etching.
[0013] In another embodiment of the method, the support film outside of the opening is removed by dry etching, and further the conductive material outside of the opening is removed to at least the surface of the substrate assembly by wet etching and/or dry etching.
[0014] In yet another embodiment of the method, the support film outside of the opening is removed by wet etching, and further the conductive material outside of the opening is removed to at least the surface of the substrate assembly by wet etching and/or dry etching.
[0015] Another method of providing a conductive material in an opening according to the present invention includes providing a substrate assembly having at least one surface and providing an opening defined through the surface of the substrate assembly. The opening is defined by at least one surface. At least one conductive material is formed within the opening on the at least one surface defining the opening and on at least a portion of the substrate assembly surface. At least one support material is formed over the at least one conductive material and at least the support material and the at least one conductive material outside of the opening is removed to at least the substrate assembly surface by planarization. Thereafter, the support material within the opening is removed.
[0016] In one embodiment of the method, forming the support material includes forming a support film over the at least one conductive material and forming a fill material over at least a portion of the support film. The fill material at least fills the opening. Further, at least the fill material outside of the opening, the support film outside of the opening and the at least one conductive material outside of the opening is planarized to at least the substrate assembly surface.
[0017] In another method of providing a conductive material in an opening according to the present invention, the method includes providing a substrate assembly having at least one surface and providing an opening defined through the surface of the substrate assembly. The opening is defined by at least one surface. At least one conductive material is formed within the opening on the at least one surface defining the opening and on at least a portion of the substrate assembly surface. At least a support material is formed over the at least one conductive material. At least the support material outside of the opening is removed to the at least one conductive material by planarization. Thereafter, the at least one conductive material outside the opening and the support material within the opening are removed.
[0018] In one embodiment of the method, forming the support material includes forming a support film over the at least one conductive material. The support film outside the opening is planarized to the at least one conductive material. Further, the at least one conductive material outside the opening is removed to at least the substrate assembly surface using a wet etch and/or dry etch.
[0019] In yet another embodiment of the method, the support material at least fills the opening and the at least one conductive material outside the opening is removed to at least the substrate assembly surface using a wet etch and/or a dry etch.
[0020] Another method of providing a conductive material in an opening according to the present invention is described. The method includes providing a substrate assembly having at least an upper surface and providing an opening defined through the upper surface of the substrate assembly. The opening is defined by at least one surface. A stack of at least one conductive material, a support film, and a fill material is formed within the opening and on at least a portion of the upper surface. The opening is entirely filled by the stack. At least the fill material outside of the opening is removed followed by the removal of the support film outside of the opening, the removal of the conductive material outside of the opening, the removal of the fill material within the opening, and the removal of the support film within the opening.
[0021] In one embodiment of the method, the support film and the at least one conductive material outside of the opening is removed to at least the surface of the substrate assembly by planarization.
[0022] In yet another embodiment, the support film outside of the opening is removed by planarization, and further the at least one conductive material outside of the opening is removed to at least the upper surface of the substrate assembly by a wet etch and/or a dry etch.
[0023] Yet further, in another embodiment, the support film outside of the opening is dry etched, and further a wet etch and/or a dry etch is used to remove the at least one conductive material outside of the opening to at least the upper surface of the substrate assembly.
[0024] Yet further, in another embodiment, the support film is wet etched, and further a wet etch and/or a dry etch is used to remove the at least one conductive material outside of the opening to at least the upper surface of the substrate assembly.
[0025] In many embodiments of the methods described above, the fill material within the opening is removed using a wet etch and/or a dry etch, the fill material is formed of a material that is removed at a rate faster than material at the surface of the substrate assembly during removal of the fill material by the wet etch and/or the dry etch, the support film within the opening is removed using a wet etch and/or a dry etch, and/or the support film is formed of a material that is removed at a rate faster than material at the surface of the substrate assembly during removal of the support film by the wet etch and/or the dry etch.
[0026] The methods described above may be used to form a first electrode on the bottom surface and the at least one side wall of a defined opening. Thereafter, a dielectric material may be provided on at least a portion of the first electrode and a second electrode may be provided on at least a portion of the dielectric material.
[0027] A structure for use in providing a conductive material in a opening according to the present invention includes a substrate assembly (e.g., an assembly having an insulative material at the surface) including an opening defined through an upper surface thereof. The opening is defined by at least one surface. At least one conductive material (e.g., a Group VIII metal such as platinum and/or metal rhodium) is formed on the at least one surface defining the opening and at least a portion of the upper surface of the substrate assembly. A support film (e.g., an oxide material) is formed over the at least one conductive material and a fill material (e.g., a resist material) is formed over at least a portion of the support film. The fill material at least fills the opening.
[0028] In one embodiment of the structure, the support film is formed of a material that is removed at a rate faster than the material at the upper surface of the substrate assembly when subjected to a predetermined etch.
[0029] In another embodiment of the structure, the fill material is formed of a material that is removed at a rate faster than the material at the upper surface of the substrate assembly when subjected to a predetermined etch process.
[0030] In yet another embodiment, the conductive material is formed only within the opening on a bottom surface and at least one side wall defining the opening, the support film is formed only within the opening over the at least one conductive material, and further the fill material is formed only within the opening.
[0031] The above summary of the present invention is not intended to describe each embodiment of every implementation of the present invention. Advantages, together with a more complete understanding of the invention, will become apparent and appreciated by referring to the following detailed description and claims taken in conjunction with the accompanying drawings.
[0032] The present invention will be better understood from reading the following description of illustrative embodiments with reference to the attached drawings, wherein below:
[0033]
[0034] FIGS.
[0035]
[0036] FIGS.
[0037] FIGS.
[0038] FIGS.
[0039] FIGS.
[0040] FIGS.
[0041] FIGS.
[0042] Various alternate methods and structures according to the present invention shall be described generally with reference to FIGS.
[0043] FIGS.
[0044] As used in this application, “substrate assembly” refers to either a semiconductor substrate such as the base semiconductor layer, e.g., the lowest layer of silicon material in a wafer, or a silicon layer deposited on another material such as silicon on sapphire, or a semiconductor substrate having one or more layers or structures formed thereon or regions formed therein. When reference is made to a substrate assembly in the following description, various process steps may have been previously used to form or define regions, junctions, various structures, or features and openings such as transistors, active areas, diffusions, implanted regions, vias, contact openings, high aspect ratio openings, etc.
[0045] For example, substrate assembly
[0046] Further, for example, first portion
[0047] Further, for example, the substrate assembly
[0048] As described herein, small high aspect ratio openings have feature sizes or critical dimensions below about 1 micron (e.g., such as diameter or width of an opening being less than about 1 micron). Further, such small high aspect ratio openings have aspect ratios greater than about 1. Such critical dimensions and aspect ratios are applicable to contact holes, vias, trenches, and any other configured openings. For example, a trench having an opening width of 1 micron and a depth of 3 microns has an aspect ratio of 3.
[0049] As used herein, “planarization” refers generally to the mechanical removal of material at a wafer surface, e.g., the flattening and polishing process used during typical wafer fabrication processes. For example, such planarization may include chemical mechanical polishing, chemical mechanical planarization, planarization using pads and abrasive slurries, planarization using fixed abrasive pads, planarization using fixed abrasive pads in combination with slurries and/or other fluid compositions, or any other mechanical surface material removal method for providing a flattening of surfaces of a wafer during the wafer fabrication process. The present invention is not limited to any particular planarization equipment. Further, any number of planarization process steps may be used, e.g., repeated planarization for several periods of time, cleaning steps, etc.
[0050] As used herein, “dry etch” refers to any process using a plasma to remove material in wafer fabrication. Therefore, for example, dry etching as used herein includes not only the use of reactive gases energized by a plasma to remove material via volatilization of material, but also includes sputter etching or ion milling, e.g., argon energized by plasma to physically sputter and remove material from a surface. Further, as used herein, a “wet etch” refers to any etching or removal of material by way of a liquid composition, e.g., the removal of material by exposure to a liquid composition, such as by immersion. One skilled in the art will recognize that various dry etch and wet etch processes are known and that the present invention contemplates the use of various types of such processes in achieving the desired result as further described herein; such processes being particularly dependent on the materials being removed.
[0051] Although the present invention is described generally below with respect to the formation of any conductive material within an opening, the present invention is particularly advantageous to the formation of conductive material including one or more Group VIII metals. In other words, the processes described herein are applicable to the formation of material, wherein the material includes one or more Group VIII metals, e.g., metals or metal alloys. More preferably, the present invention is particularly applicable to the Group VIII metals including platinum, palladium, ruthenium, iridium, osmium, and rhodium, and further any metal alloys thereof, e.g., platinum-rhodium.
[0052] Further, with reference to FIGS.
[0053] After the conductive material, e.g., one or more conductive layers
[0054] Any method of forming the support film
[0055] After forming support film
[0056] After the stack of materials, including the conductive material
[0057] The support film
[0058] After the planarization process is performed, the resultant structure is shown in
[0059] Thereafter, the fill material
[0060] After the fill material
[0061] As shown in
[0062] It will be recognized that the conductive material
[0063] FIGS.
[0064] In this illustrative method, a stack of materials substantially the same as shown in
[0065] After planarization, the conductive material
[0066] The removal of the conductive material
[0067] Following the removal of the conductive material
[0068] Another illustrative alternate embodiment of a method for forming the conductive material in an opening is shown in FIGS.
[0069] With the planarization process stopping or having its end point on the upper surface
[0070] The resultant structure following such a wet etch and/or dry etch of the support film
[0071] With the conductive material
[0072] In yet another alternate illustrative embodiment of the method for forming conductive material within an opening, a method similar to that described with reference to FIGS.
[0073] As shown in
[0074] Upon formation of the stack of layers on substrate assembly
[0075] Thereafter, a wet etch and/or dry etch is used to remove the portions of the one or more conductive layers
[0076] It will be recognized that the planarization process may also use the upper surface
[0077] As further shown in
[0078] A final alternate illustrative embodiment of a method of forming conductive material within an opening is shown in FIGS.
[0079] The substrate assembly
[0080] In this particular embodiment, the support material
[0081] After formation of the support material
[0082] Thereafter, the conductive material
[0083] Thereafter, the support material
[0084] Two illustrations of using the above described methods of forming conductive material in an opening are described below with reference to FIGS.
[0085] As shown in
[0086] As shown in