High performance flash memory devices

A flash memory device includes a wafer; a gate oxide layer disposed upon the wafer; a floating gate disposed upon the gate oxide layer, the wafer, or a combination thereof; the floating gate including a flat floating gate portion and a generally rectangular floating gate portion disposed upon selected areas of the flat floating gate portion; a high K dielectric material disposed upon the floating gate; and a control gate disposed upon the high K dielectric material; wherein the high K dielectric material forms a zigzag pattern coupling the floating gate with the control gate.

BACKGROUND

This disclosure relates to a semiconductor device, and more particularly, to a flash memory device and a method for manufacturing the same.

Memory devices are typically provided as internal storage areas in the computer. The term memory identifies data storage that comes in the form of integrated circuit chips. There are several different types of memory used in modern electronics, one common type is RAM (random-access memory). RAM is characteristically found in use as main memory in a computer environment. RAM functions as a read and write memory; that is, data may be written into RAM and data may be read from RAM. This is in contrast to read-only memory (ROM), which permits only reading of data. Most RAM is volatile, which means that it requires an uninterrupted source of power to maintain its contents. As soon as the power is turned off, whatever data was in RAM is lost.

Computers almost always contain a small amount of ROM that holds instructions for starting up the computer. Unlike RAM, ROM cannot be written to. An EEPROM (electrically erasable programmable read-only memory) is a special type non-volatile ROM that can be erased by exposing it to an electrical charge. EEPROM comprise a memory array which includes a large number of memory cells having electrically isolated gates. Data is stored in the memory cells in the form of charge on the floating gates or floating nodes associated with the gates. Each of the cells within an EEPROM memory array can be electrically programmed in a random basis by charging the floating node. The charge can also be randomly removed from the floating node by an erase operation. Charge is transported to or removed from the individual floating nodes by specialized programming and erase operations, respectively.

Yet another type of non-volatile memory is a Flash memory. A Flash memory is a type of EEPROM that is typically erased and reprogrammed in blocks instead of a single bit or one byte (8 or 9 bits) at a time. A typical Flash memory comprises a memory array, which includes a large number of memory cells. Each of the memory cells includes a floating gate field-effect transistor (FET) capable of holding a charge. The data in a cell is determined by the presence or absence of the charge in the floating gate/charge trapping layer. The cells are usually grouped into sections called “erase blocks.” Each of the cells within an erase block can be electrically programmed in a random basis by charging the floating gate. The charge can be removed from the floating gate by a block erase operation, wherein all floating gate memory cells in the erase block are erased in a single operation.

The memory cells of both an EEPROM memory array and a Flash memory array are typically arranged into either a “NOR” architecture (each cell directly coupled to a bit line) or a “NAND” architecture (cells coupled into “strings” of cells, such that each cell is coupled indirectly to a bit line and requires activating the other cells of the string for access).

One problem in Flash memory cell arrays is that voltage scalability affects the minimum cell size, and consequently the overall memory density of any resulting array. As integrated circuit (IC) processing techniques improve, manufacturers try to reduce the feature sizes of the devices produced and thus increase the density of the integrated circuits and memory arrays. In modern integrated circuits and memory arrays, as SONOS (Silicon-Oxide-Nitride-Oxide-Silicon) transistors and floating gate memory cells are scaled to smaller feature sizes, the device characteristics of the component transistors and floating gate memory cells can alter and leave the resulting IC or memory device non-functional. These issues include, but are not limited to, short channel effect, signal cross-talk, device programming and operating voltages, reduced logic windows, oxide punch-through, and charge leakage and retention.

Commercially available flash memory generally includes a planar control gate, a planar floating gate, and two interposed dielectric layers. The planar control gate, floating gate, and two dielectric layers are disposed upon a semiconductor substrate.

Due to the two layers of dielectric material in conventional flash memory, it is difficult to scale down the gate length of flash memory. Scaling of the device requires scaling down the gate dielectric, including both gate dielectric layers have been scaled down. Aggressive scaling of gate dielectric thickness may cause large leakage current from the floating gate. This will reduce memory life time of the devices.

For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for methods and apparatus for a non-volatile memory cell that allows for feature and voltage scaling, prevents read degradation while providing enhanced retention, speed, endurance, and exhibits increased device integrity.

SUMMARY

Disclosed herein is a flash memory device comprising: a wafer; a gate oxide layer disposed upon the wafer; a floating gate disposed upon the gate oxide layer, the wafer, or a combination thereof; the floating gate comprising a flat floating gate portion and a generally rectangular floating gate portion disposed upon selected areas of the flat floating gate portion; a high K dielectric material disposed upon the floating gate; and a control gate disposed upon the high K dielectric material; wherein the high K dielectric material forms a zigzag pattern coupling the floating gate with the control gate.

Also disclosed herein is a method of manufacturing a flash memory device comprising: forming a gate oxide on a wafer; disposing a first floating gate layer on the wafer; disposing a second floating gate layer on the first floating gate layer; patterning a resist mask over the second floating gate layer; etching to remove at least a portion of the unprotected portions of the second floating gate layer, wherein the first floating gate layer remains substantially intact; wherein the etching defines a second floating gate layer having a plurality of generally rectangular shapes disposed upon the first floating gate layer, wherein the first floating gate layer is substantially flat; removing the resist mask; disposing a high K dielectric material on the second floating gate layer and the first floating gate layer; and disposing a control gate layer on the high K dielectric material; wherein the high K dielectric material forms a zigzag pattern coupling the second floating gate layer and the first floating gate layer with the control gate layer.

DETAILED DESCRIPTION

As disclosed herein, the flash memory device comprising a “zigzag” capacitance between the control gate and the floating gate has a greater capacitance than a device comprising a conventional flat capacitance between the planar control gates and floating gates. The zigzag capacitance increases coupling (control) of the control gate to the floating gate and then to the channel. This improves short-channel effect and allows for improved scaling.

Disclosed herein is a flash memory device comprising: a wafer; a gate oxide layer disposed upon the wafer; a floating gate disposed upon the gate oxide layer, the wafer, or a combination thereof; the floating gate comprising a flat floating gate portion and a generally rectangular floating gate portion disposed upon selected areas of the flat floating gate portion; a high K dielectric material disposed upon the floating gate; and a control gate disposed upon the high K dielectric material; wherein the high K dielectric material forms a zigzag pattern coupling the floating gate with the control gate.

Also disclosed herein is a method of manufacturing a flash memory device comprising: forming a gate oxide on a wafer; disposing a first floating gate layer on the wafer; disposing a second floating gate layer on the first floating gate layer; patterning a resist mask over the second floating gate layer; etching to remove at least a portion of the unprotected portions of the second floating gate layer, wherein the first floating gate layer remains substantially intact; wherein the etching defines a second floating gate layer having a plurality of generally rectangular shapes disposed upon the first floating gate layer, wherein the first floating gate layer is substantially flat; removing the resist mask; disposing a high K dielectric material on the second floating gate layer and the first floating gate layer; and disposing a control gate layer on the high K dielectric material; wherein the high K dielectric material forms a zigzag pattern coupling the second floating gate layer and the first floating gate layer with the control gate layer.

It will be understood that when an element or layer is referred to as being “on,” “interposed,” “disposed,” or “between” another element or layer, it can be directly on, interposed, disposed, or between the other element or layer or intervening elements or layers may be present.

As used herein, the singular forms “a,” “an” and “the” are intended to comprise the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. In flash memory design, it is desired that the capacitance between the control gate and the floating gate is maximized while at the same time minimizing any leakage current through the dielectric layer. The present inventors have unexpectedly discovered that the nonplanar process disclosed herein provides significantly improved coupling between the control gate and the floating gate as compared to conventional flash memory that uses planar floating gates and control gates. The nonplanar process is advantageous because it provides increased capacitance by increasing the area of dielectric, which can increase the controllability of the control gate to channel. This allows for additional scaling down of gate length.

As used herein, the terms wafer and substrate include any base semiconductor structure, including but not limited to, a bulk silicon substrate structure, a silicon-on-sapphire (SOS) structure, a silicon-on-insulator (SOI) structure, a silicon-on-nothing (SON) structure, a thin film transistor (TFT) structure, a doped or undoped semiconductor, or a structure comprising epitaxial layers of silicon supported by a base semiconductor, as well as other semiconductor structures well known to one skilled in the art. Furthermore, when reference is made to a wafer or substrate in the following description, previous process steps may have been utilized to form regions/junctions in the base semiconductor structure. The substrate190may include a bulk silicon or a silicon-on-insulator (SOI) structure, for example, although other semiconductor materials such as germanium, silicon germanium, silicon germanium-on-insulator, silicon carbide, indium antimonide, indium arsenide, indium phosphide, gallium arsenide, gallium arsenide, etc., are also contemplated. An exemplary semiconductor structure is a silicon-on-insulator (SOI) structure.

Referring toFIGS. 1 through 10B, there is shown a sequence of top and cross sectional views illustrating a method of forming gate structures for flash memory devices, in accordance with one embodiment. It is to be noted that in the text as well as in all of the Figures, the respective structures will be termed the “device” and will be referred to by the number “100” though the device is not yet a flash memory device100until the last stages of manufacturing described herein. This is done primarily for the convenience of the reader.

In an embodiment disclosed inFIGS. 1A and 1B, a flash memory device comprises a control gate110disposed upon a gate dielectric layer120. The gate dielectric layer120is disposed upon a floating gate130. The floating gate130is disposed upon a gate oxide140. As shown inFIGS. 1A and 1B, these components are stacked in a vertical arrangement. The a control gate110is on top of a gate dielectric layer120, which is on top of a floating gate130, which is on top of a gate oxide140. As shown inFIGS. 1A and 1B, a nitride spacer150is disposed on the sides of the vertically arranged control gate110; gate dielectric layer120; floating gate130; and gate oxide140. As shown inFIGS. 1A and 1B, the gate oxide140is disposed upon a wafer190.

In one embodiment, the wafer190comprises a semiconductor-on-insulator (SOI) structure160having a buried oxide (BOX) layer170and an adjoining substrate180. In an exemplary embodiment, the gate oxide140is disposed upon the SOI structure160of the wafer190. The substrate180may comprise germanium, silicon, or a combination of germanium and silicon such as silicon-germanium. In an exemplary embodiment, the semiconductor substrate180comprises silicon. The substrate180has a BOX layer170disposed thereon. In one embodiment, the BOX layer170can comprise silicon dioxide produced by doping the silicon substrate180with oxygen as a dopant. An ion beam implantation process followed by high temperature annealing can be used to form a BOX layer170. In another embodiment, the SOI wafer can be manufactured by wafer bonding, where the BOX layer170and the SOI layer160can be separately adhered to the substrate180.

The silicon-on-insulator (SOI) layer160is disposed upon the BOX layer113and generally has a thickness of about 50 to about 210 nanometers. In one embodiment, the SOI layer is implanted with a P+ dopant such as boron or an N+ dopant such as arsenic, phosphorus and gallium and annealed to activate the dopant. In another embodiment, the source/drain and extension areas of the SOI layer are implanted with a P+ dopant or an N+ dopant and annealed to activate the dopant. The dopant is generally added in a concentration of about 1019to about 1021atoms/cm3.

According to another embodiment, the gate dielectric layer120is a deposited dielectric material, such as, for example, a high K dielectric material, including, for example, hafnium oxide, hafnium silicon oxide, lanthanum oxide, zirconium oxide, zirconium silicon oxide, tantalum oxide, titanium oxide, barium strontium titanium oxide, barium titanium oxide, strontium titanium oxide, yttrium oxide, aluminum oxide, lead scandium tantalum oxide, lead zinc niobate, or a combination of at least one of the foregoing high K dielectric materials. An exemplary dielectric material is hafnium oxide (HfO2). Although not specifically shown in the Figures, the gate stack may also include another high K dielectric layer formed on gate dielectric layer120. The gate dielectric layer120may be formed on the substrate100and STI regions using a deposition method, e.g., a chemical vapor deposition (CVD), a low pressure CVD, a plasma enhanced CVD (PECVD), an atomic layer CVD, a physical vapor deposition (PVD), or a combination of at least one of the foregoing deposition methods.

FIG. 1Bis another cross-sectional view of the flash memory design having a zigzag capacitance between the control and floating gates, orthogonal to the view shown inFIG. 1A. In this view, it will be seen that the gate dielectric layer120is disposed upon floating gate130that comprises a generally rectangular floating gate portion210and a substantially flat basal floating gate portion200. As used herein, “generally rectangular” refers to a substantially square or rectangular geometric shape.

In one embodiment, the floating gate130comprises a material such as poly-Si, poly-SiGe, a conductive metal, such as tungsten and molybdenum, a conductive metal nitride, such as titanium nitride, tantalum nitride, and tungsten nitride, or a combination comprising at least one of the foregoing materials. In one embodiment, the generally rectangular floating gate portion210comprises poly-SiGe, a conductive metal, such as tungsten and molybdenum, a conductive metal nitride, such as titanium nitride, tantalum nitride, and tungsten nitride, or a combination comprising at least one of the foregoing materials. In one embodiment, the flat basal floating gate portion200comprises poly-Si. In another embodiment, the generally rectangular floating gate portion210comprises poly-SiGe and the flat basal floating gate portion200comprises poly-Si.

In one embodiment, the control gate110comprises a material such as poly-Si, poly-SiGe, a conductive metal, such as tungsten and molybdenum, a conductive metal nitride, such as titanium nitride, tantalum nitride, and tungsten nitride, or a combination comprising at least one of the foregoing materials. In one embodiment, the control gate110comprises poly-Si.

As shown inFIG. 1B, the gate dielectric layer120is disposed upon both the generally rectangular floating gate portion210and the flat basal floating portion200. The generally rectangular floating gate portion210is disposed upon the flat basal floating gate portion200, which, in turn, is disposed upon the gate oxide140. Referring now to bothFIGS. 1A and 1B, the control gate110substantially covers the rectangular floating gate portion210in a tongue-in-groove or intercalating comb-like structure. The interposed gate dielectric120thus forms a zigzag pattern as it couples the control gates110and floating gates130. The basal floating gate portion200is not covered by the control gate110and thus is visible in the cross-section view shown inFIG. 1A.

FIGS. 2-10are various top and cross-sectional views illustrating an exemplary method of forming the structure shown inFIGS. 1A and 1B.

FIG. 2is a top view of a silicon trench isolation (STI) formed on a wafer. The STI oxide of the BOX layer160surrounds the active area of the SOI layer170.FIG. 3shows a cross-section of the wafer190cut along A-A that shows the SOI layer160; the BOX layer170; and the substrate180.

FIG. 4is a cross-sectional view of the device100cut along A-A. following formation of a gate oxide140by thermal oxidation on the wafer190. In an embodiment, the gate oxide140may include a silicon dioxide dielectric film grown with a dry/wet oxidation process. In an embodiment, the silicon oxide film may be grown to a thickness of between about 5 to about 15 Angstroms. A first floating gate layer200is disposed on the wafer190and the gate oxide140. A second floating gate layer210is disposed on the first floating gate layer200.

FIG. 5is a top view of the device100having a resist mask220patterned over the STI oxide of the BOX layer170and the active area of the SOI layer160. In one embodiment, the resist mask is patterned in parallel stripes that are substantially parallel to A-A.

As shown inFIGS. 6A and 6B, following patterning, a resist mask220is disposed upon on the second floating gate layer210.FIG. 6Ashows a cross-section cut along A-A, where no resist mask is present. Thus, looking at this cross-section,FIG. 6Ashows a first floating gate layer200disposed on the wafer190and the gate oxide140, and a second floating gate layer210disposed on the first floating gate layer200.FIG. 6Bshows a cross-section cut along B-B, where a resist mask is present. Looking at this cross-section,FIG. 6Bshows a resist disposed on the second floating gate layer210.

Following the patterning of the resist220, a reactive ion etch (RIE) is performed that selectively removes the unprotected second floating gate layer210leaving the first floating gate layer200. In another embodiment, the RIE partially removes the second floating gate layer210leaving a layer of poly-SiGe (not shown) disposed upon the first floating gate layer200. As shown inFIGS. 7A and 7B, following the RIE, the unprotected poly-SiGe layer is removed210.FIG. 7Ais a cross-sectional view cut along A-A, where no resist mask220is present, after etching.FIG. 7Ashows a first floating gate layer200disposed on the wafer190and the gate oxide140.FIG. 7Bis a cross-sectional view cut along B-B, where a resist mask220is present, after etching. Looking at this cross-section,FIG. 7Bshows the protected second floating gate layer210is now formed into generally rectangular shapes after the RIE.

Following the RIE of the second floating gate layer210, the resist220is removed. Following removal of the resist, a high-dielectric material120is then disposed on the entire device100to a depth of about 3 to about 5 nanometers. Another layer of in-situ doped poly-Si200is subsequently disposed on the high-dielectric material120. As shown inFIGS. 8A and 8B, the device100now comprises a control gate layer110disposed on a high-dielectric material layer120that is in turn disposed on a second floating gate layer210that is formed into generally rectangular shapes and a flat basal first floating gate layer200.FIG. 8Ais a cross-sectional view cut along A-A. In this view,FIG. 8Ashows a control gate layer110disposed on a high-dielectric material layer120that is in turn disposed on a flat basal first floating gate layer200.

FIG. 8Bis a cross-sectional view cut along B-B. Looking at this cross-section,FIG. 8Bshows a control gate layer110disposed on a high-dielectric material layer120that is in turn disposed on a second floating gate layer210that is formed into generally rectangular shapes and a flat basal first floating gate layer200. The interposed high K dielectric material120thus forms a zigzag pattern as it couples the control gate layer110and the rectangular second floating gate layer210and the flat first floating gate layer200. The rectangular second floating gate layer210is substantially covered by the control gate layer110and thus is hidden in the cross-section view shown inFIG. 8A.

Following formatting of the zigzag pattern, the device is further patterned by a series of resists, depositions, patterning, and etches to pattern the control gate layer110, the high-dielectric material layer120, and the second floating gate layer210and the first floating gate layer200to form a gate conductor.FIGS. 9A and 9B. The etching can all be accomplished via RIE. In one embodiment, a single RIE may be conducted to remove all the layers. In another embodiment, different RIEs may be conducted to remove different layers. For example, a first RIE may be conducted to remove the control gate layer110. A second RIE may be conducted to remove the high-dielectric material layer120, while a third and fourth RIE may be conducted to remove the second floating gate layer210and the first floating gate layer200, respectively. The RIE can be conducted with halogenated compounds such as CHF3, Cl2, CF4, SF6, or the like, or a combination comprising at least one of the foregoing halogenated compounds.

In one embodiment, other process may be performed to complete the building of the device100. These processes include, for example, halo and extension implant; spacer formation, and SD implant and SD anneal to activate dopants.FIGS. 10A and 10Bshow cross-section views of a finished embodiment of the device100.

In the embodiment disclosed inFIGS. 2-10B, the floating gate130comprises a material such as poly-Si, poly-SiGe, a conductive metal, such as tungsten and molybdenum, a conductive metal nitride, such as titanium nitride, tantalum nitride, and tungsten nitride, or a combination comprising at least one of the foregoing materials. In one embodiment, the first floating gate portion200comprises poly-Si. In one embodiment, the second floating gate portion210comprises poly-SiGe, a conductive metal, such as tungsten and molybdenum, a conductive metal nitride, such as titanium nitride, tantalum nitride, and tungsten nitride, or a combination comprising at least one of the foregoing materials. In another embodiment, the first floating gate portion200comprises poly-Si and the second floating gate portion210comprises poly-SiGe.

In one embodiment, the control gate110comprises a material such as poly-Si, poly-SiGe, a conductive metal, such as tungsten and molybdenum, a conductive metal nitride, such as titanium nitride, tantalum nitride, and tungsten nitride, or a combination comprising at least one of the foregoing materials. In one embodiment, the control gate110comprises poly-Si.

This device is advantageous in that the capacitance between the zigzag control gate and the floating gate is greater than that of a flat gate structure, which, in turn, increases coupling of the control gate to the floating gate and then to the channel. This improves short-channel effect and allows for improved scaling to reduce the size of the flash memory device.)