Thin-film structure with conductive molybdenum-chromium line

Abstract: A conductive line (72-76; Fig.3) in a thin-film structure such as an AMLCD array (Fig.3) includes molybdenum and chromium so that it can be processed in a manner similar to chromium but has a greater conductivity than chromium due to the molybdenum. The conductive line (72-76; Fig.3) can be produced by physical vapor deposition (30) of a layer of a molybdenum-chromium (MoCr) alloy, which can then be masked (32) and etched (34) using photolithographic techniques in a manner similar to chromium. Proportions between 15 and 85 atomic percent of molybdenum can be processed more easily than pure molybdenum and are more conductive than pure chromium. Lines with between 40 and 60 atomic percent molybdenum can be used with a margin of error. To produce a tapered conductive line (Fig.9), sublayers of MoCr alloys with different etch rates can be produced and etched.

Description: The present invention relates to structures comprising thin-film structures and methods of manufacturing thin-film structures. Noriyama et al., in US-A-5,132,819, describe a liquid-crystal display device of active matrix type. As shown and described in relation to Figs 4 and 5, a chromium (Cr) film is formed by sputtering on the upper surface of an insulating substrate of glass or the like. The chromium film is photo-etcned to form a gate electrode, an auxiliary capacitance line, and a conductor. A scanning line is formed integrally with the gate electrode. After several other features are formed, a molybdenum (Mo) film is formed, an aluminum (Al) film is formed on the Mo film, and the Mo-Al composite film is photo-etched to form a drain electrode, a source electrode, and a signal line (i.e. a column-selecting line). Hikichi et al., in US-A-5,279,980, describe techniques for manufacturing a thin-film semiconductor device having an alpha-tantalum first wiring member. As described at col. 1 line 57-col. 2 line 5, first wiring members such as gate electrodes, source electrodes, drain electrodes, and signal wirings must be made of a conductive material that has good adhesion to a glass substrate and that is sufficiently heat-resistant to avoid deterioration in subsequent heat treatments. High-melting-point (refractory) metals such as tantalum (Ta), molybdenum (Mo), titanium (Ti), and chromium (Cr) have conventionally been used, with tantalum used most extensively. Col. 2 lines 15-23 indicates that tantalum alloys such as TaW and TaMo are used in some areas, but that a resulting anodic oxidation film will not contribute to a higher withstand voltage and that such alloys are less conductive than α-tantalum. Structures with TaMo alloys are shown and described in relation to Figs. 1-9B. The invention provides a method of forming a thin-film structure at a surface of a substrate as defined in claim 1; and a structure as defined in claim 6 which includes a conductive line of molybdenum (Mo) and chromium (Cr). The alloy has from 15 to 85 atomic percent of molybdenum. The invention can be implemented by physical vapor deposition of Mo and Cr such that the resulting molybdenum-chromium (MoCr) layer can be processed in somewhat the same way as if it were Cr, yet has greater conductivity than pure Cr. Mo and Cr can be sputtered from separate Mo and Cr targets by moving the substrate past the targets in succession. Alternatively, both Mo and Cr can be sputtered from a single alloy target. After an MoCr layer is formed, a pattern of mask material can be formed using lithographic techniques, and an etch can remove areas not covered by the pattern. The pattern includes a part that has the shape of a conductive line covering a part of the MoCr layer, so that the covered part forms an MoCr conductive line. Then the mask material can be removed from over the conductive line. Tests have shown that an MoCr layer can be wet etched similarly to Cr. Tests have also shown that an MoCr layer with 50 percent molybdenum or less is, like Cr, unaffected by cleaning with a solution containing NH 4 OH and H 2 O 2 , a solution that would remove a pure Mo layer. Pure Mo, on the other hand, is subject to severe attack by many etchants commonly used in producing thin-film structures, including etchants for silicon such as a solution containing H 3 PO 4 , HNO 3 , and HF and etchants for aluminum such as H 3 PO 4 , CH 3 COOH, and HNO 3 and also H 2 SO 4 and H 2 O 2 . Many different atomic proportions of Mo and Cr would form a layer that can be processed more easily than pure Mo but has greater conductivity than pure Cr. Tests have shown that a layer with any proportion between 15 and 85 atomic percent of molybdenum meets this criterion. In practical applications, conductive lines with between 40 and 60 atomic percent molybdenum can be used with a satisfactory margin of error. The invention may be implemented with conductive lines that include approximately 40 to 60 atomic percent molybdenum with the balance being chromium. In addition, different atomic proportions of Mo and Cr can be used to produce MoCr layers with different etch rates. The etching process can then produce a tapered MoCr line, greatly reducing problems with step coverage even for a relatively thick conductive line. MoCr conductive lines according to the invention may be used as scan lines in an array of light control units for an active matrix liquid crystal display (AMLCD). Each light control unit can include a thin-film transistor (TFT), and each conductive line can, for example, be a scan line for providing signals to the gates of a set of the TFTs. Each scan line can be connected, for example, to the TFTs in a row of light control units. The invention is advantageous compared to several conventional techniques: In comparison with Cr lines on an insulating substrate, MoCr alloy lines can be etched similarly but have lower sheet resistivity and film stress, allowing thicker films, which in turn shortens RC delay time. A typical 100nm (1000 Å) thick sputter deposited Cr film has sheet resistivity in the range of 10 to 30 ohms/sq. depending on deposition conditions. Cr films deposited at higher argon (Ar) gas pressure have lower stress and therefore are less susceptible to film cracking during subsequent processing; unfortunately, such films also have higher resistivity. In contrast, a film of MoCr alloy deposited under normal sputtering conditions has much lower film stress and resistivity: A 100nm (1000 Å) thick MoCr film has been successfully fabricated with close to zero stress and less than 3 ohms/sq. As array size increases, MoCr alloy lines perform better than Cr lines because MoCr has lower resistance and therefore a lower RC delay time. The MoCr alloy system permits fine tuning of some properties by changing alloy composition--film stress, wet etch rate in Cr etch, and resistance to some other chemical etchants are examples of properties that can be fine tuned. In addition, the MoCr alloy system can be varied within a layer to provide different etch rates, permitting tapered edges. In comparison with Al lines, MoCr is a high temperature refractory metal, so that it can sustain high temperature processing such as 300-400° C, the typical range for chemical vaper dielectric deposition in display fabrication. Aluminium, on the other hand, forms hillocks in high temperature processing. Hillocks are a major cause of device failure when Al lines are used. In comparison with Mo-Ta alloy lines, MoCr lines can be produced using wet etch techniques applicable to Cr, while Mo-Ta lines can only be produced using dry etch processes such as plasma etching, which are expensive and often have uniformity problems. MoCr lines are also advantageous because the MoCr alloy system improves performance of a large area active matrix display. The following description, the drawings, and the claims further set forth these and other aspects, objects, features, and advantages of the invention. Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which: Fig. 1 is a schematic diagram showing a thin-film structure that includes a molybdenum-chromium conductive line; Fig. 2 is a flow chart showing general acts in producing an MoCr conductive line as in Fig. 1; Fig. 3 is a schematic plan view of a layout of an array of light control units with MoCr conductive lines; Fig. 4 is a plan view of a layout of a light control unit in an implementation of the array of Fig. 3; Fig. 5 is a schematic view of a sputtering chamber with a molybdenum target and a chromium target; Fig. 6 is a cross-section of an MoCr layer produced in the sputtering chamber of Fig. 5; Fig. 7 is a schematic view of a sputtering chamber with a molybdenum-chromium alloy target; Fig. 8 is a flow chart showing acts in producing a tapered conductive line that includes molybdenum and chromium; and Fig. 9 is a schematic cross-section showing a tapered conductive line produced as in Fig. 8. As used herein, an "alloy" is a material that is a macroscopically homogeneous mixture of two or more metals. In an alloy or other mixture of two or more elements, the relationship between the quantities of atoms of the elements can be expressed as an "atomic percent," an "atomic proportion," or an "atomic ratio." "MoCr" or "molybdenum-chromium" means an alloy of molybdenum and chromium. MoCr could also include traces of one or more additional metals which do not affect film properties. Figure 1 shows a thin-film structure that includes a molybdenum-chromium (MoCr) conductive line, and Fig. 2 shows general acts in producing an MoCr conductive line. Product 10, shown in cross-section in Fig. 1, includes substrate 12 with surface 14 at which thin-film structure 16 is formed. Thin-film structure 16 includes conductive line 18, which in turn includes molybdenum-chromium. Conductive line 18 could be on surface 14 but, as suggested by the ellipses in Fig. 1, thin-film structure 16 can also include one or more layers between MoCr conductive line 18 and surface 14. Thin-film structure 16 can also include one or more layers above MoCr conductive line 18. In Figure 2, the first step 30 is that of performing physical vapor deposition (PVD) to produce a layer that includes molybdenum-chromium. Next (step 32) lithography to produce a pattern of mask material that covers a part of the MoCr layer that has the shape of a conductive line is carried out. The following step 34 comprises etching to remove areas not covered by the pattern of mask material from box 32. As a result of the etch at step 34, the covered part of the MoCr layer forms an MoCr conductive line. Then, step 36 comprises removing the pattern of mask material from the MoCr conductive line. The general features described above could be implemented in numerous ways to provide a thin-film structure with an MoCr conductive line. As described below, the general features have been implemented in a number of ways. Figure 3 shows a partial layout of an array with MoCr scan lines, and Fig. 4 shows a layout of a light control unit in the array of Fig. 3. Array 70 in Fig. 3 includes scan lines 72, 74, through 76 and data lines 80, 82, through 84. Scan lines 72, 74, through 76 are MoCr conductive lines, with scan lines 74 through 76 each connected to a row of light control units to provide a signal selecting the light control units in that row. Illustrative light control unit 90, for example, receives its signal from scan line 74. In some implementations, each light control unit in array 70 could receive a binary scan signal from its scan line, so that the light control unit is either selected or not. Therefore, conductivity of scan lines is important--as conductivity declines, the scan signal becomes damped and delayed. MoCr conductive lines provide sufficient conductivity to alleviate this problem. Figure 4 shows a light control unit and specifically shows several layers of a thin-film structure, with upper layers that are farthest from the substrate's surface obscuring lower layers. The uppermost layer shown in Fig. 4 is a top metal layer, which forms data line 110 connected to a channel lead of a transistor in the light control unit; the top metal layer also forms several other features described below. The next layer shown is a layer of indium-tin-oxide (ITO), which forms transparent electrode 112. The next layer is a top nitride layer, which forms island 114, part of the transistor. The lowest layer shown is an MoCr layer, which forms gate line 116 and, connected to it, gate lead 118, which serves as the gate lead of the transistor. Data line 110 can be implemented with a resistance of 0.2 ohm/sq. and can be driven at - 8 V, 0 V, and + 8 V. Data line 110 provides a data signal to a column of binary control units, one of which is shown in Fig. 4. The part of data line 110 that extends over gate lead 118 connects to the source lead of the transistor. Gate line 116 similarly provides a scan signal to a row of binary control units. Gate line 116 can be implemented with a resistance of 1.4 Ohm/Sq and can be driven at + 15 V and - 15V. Data line 110 and gate line 116 are each 10 µm wide. Data line 110 crosses over gate line 116 in crossover region 120. Crossover region 120 can include an insulator formed by the top nitride layer, and other features as necessary to ensure that the two lines conduct signals adequately and that signals in the two lines do not interfere. Transparent electrode 112 connects to the drain lead of the transistor through drain line 122, formed by the top metal layer. Therefore, when the transistor is conductive due to a scan signal provided to gate lead 118 by gate line 116, transparent electrode 112 receives and stores a drive signal from data line 110 through drain line 122. Transparent electrode 112 also connects to charging lead 124, which implements one electrode of a storage capacitor and is formed by the top metal layer. Gate line 126, formed by the MoCr layer, implements the other electrode of the storage capacitor; gate line 126 also provides a scan signal to the preceding binary control unit in the same column. Figure 5 shows how two targets can be used to produce an MoCr layer, and Fig. 6 illustrates an MoCr layer produced as in Fig. 5. Chamber 140 in Fig. 5 can be the vacuum chamber of a conventional magnetron sputtering machine. In chamber 140 are target 142, a pure chromium target, and target 144, a pure molybdenum target. Substrate 146 is within chamber 140, mounted so that it can be moved back and forth between a first position adjacent target 142 for deposition of chromium and a second position adjacent target 144 for deposition of molybdenum. Sputtering can be performed using conventional techniques. Figure 6 shows layer 160 formed on substrate 146. Layer 160 can be 150nm (1500 angstroms) thick, for example, and illustratively includes four very thin sublayers 162, 164, 166, and 168. Sublayers 162 and 166, for example, can be chromium, while sublayers 164 and 168 can be molybdenum. The sublayer on substrate 146 could be either molybdenum or chromium, as long as it adheres to substrate 146. If the sublayers in layer 160 are sufficiently thin, layer 160 forms an MoCr alloy due to mixing of chromium and molybdenum atoms. The technique illustrated in Figs 5 and 6 has been used successfully to produce an array as illustrated in Fig. 3. Figure 7 illustrates how a more uniform MoCr layer can be produced. The technique in Fig. 7 is the same as in Fig. 5, but with a single metal target rather than two targets. In chamber 180 in Fig. 7 are target 182, an Mo(x)Cr(y) alloy target in which x/y is the atomic ratio of Mo to Cr. Substrate 184 is also within chamber 180, mounted so that sputtering can be performed to transfer atoms from target 182 to substrate 184 in the conventional manner. Mo(x)Cr(y) alloy targets were not available in the past, apparently because such targets were not used in producing thin-film structures through sputtering. As a result of the success of this invention, however, such targets have become available from a number of sources, including Material Research Corporation, Orangeburg, New York. The technique of Fig. 7 has also been used successfully to produce an array as illustrated in Fig. 3. After production of an MoCr layer, etching and other operations can be performed using conventional techniques for obtaining chromium conductive lines. Proportions of 40 to 60 atomic percent molybdenum and 60 to 40 atomic percent chromium have produced MoCr conductive lines with the desired properties of etchability and conductivity. Figure 8 shows act in producing a tapered MoCr conductive line, and Fig. 9 shows a cross section of a tapered MoCr conductive line produced as in Fig. 8. In Fig. 8, the act in box 200 begins by performing physical vapor deposition (PVD) to produce a first sublayer that includes Mo(x 1 )Cr(1- x 1 ), an alloy in which x 1 is the atomic percentage of Mo and (1 - x 1 ) is the atomic percentage of Cr. The act in box 202 then performs physical vapor deposition (PVD) to produce a second sublayer that includes Mo(x 2 )Cr(1- x 2 ), where x 1 > x 2 so that the the etch rate of the second sublayer is significantly faster than the etch rate of the first. Together the first and second sublayers form a layer that include molybdenum and chromium, with each sublayer including an MoCr alloy. The act in box 204 performs lithography to produce a pattern of mask material that covers a part of the layer of molybdenum and chromium that has the shape of a conductive line. The act in box 206 then etches to remove areas not covered by the pattern of mask material from box 204. As a result of the etch in box 206, the covered part of the MoCr layer forms a conductive line that includes molybdenum and chromium. In addition, the act in box 206 etches differentially under the pattern boundary to produce a tapered edge on the conductive line. The act in box 208 then removes the pattern of mask material from the conductive line. Figure 9 illustrates a conductive line formed using acts like those in Fig. 8. The conductive line is formed on substrate 220, which has surface 222 at which a thin-film structure can be formed. Conductive line 230 is formed on surface 222, with lower sublayer 232 being a thickness of d 1 of Mo(x 1 )Cr(1- x 1 ) and upper sublayer 234 being a thickness of d 2 of Mo(x 2 )Cr(1- x 2 ), where x 1 > x 2 . By choosing appropriate values, conductive line 230 can be formed with a desired etch rate ratio R of the etch rate of upper sublayer 234 over the etch rate of lower sublayer 232, such that 1<R<3. For example, x 1 can be 83, d 1 4600 angstroms (460nm), x 2 87, and d 2 400 angstroms (40nm) , producing an etch rate ratio R = 2.5. The etch rate ratio and the thicknesses of the sublayers also determine the taper angle , so that both edge 286 and edge 238 of conductive line 230 are at an angle  from surface 222. Conductive line 230 is thus 5000 angstroms (500nm) thick. Techniques for producing tapered conductive lines are set forth in more detail in US-A-5 528 082 published 18.6 96, entitled "Thin Film Structure With Tapered Feature". The implementations described above use sputtering to deposit chromium and molybdenum. Other physical vapor deposition techniques could be used, such as vacuum evaporation and e-beam deposition. The implementations described above use particular atomic proportions of molybdenum and chromium, but other atomic proportions within the ranges described above could be used. The implementations described above include implementations in which an MoCr layer is homogeneous or includes sublayers. Other internal structures that result in an MoCr alloy could be used. The implementations described above generally form an MoCr layer on a glass substrate. For a top gate structure, however, the MoCr layer could be formed on a polysilicon layer rather than on the substrate, and the substrate could be an insulating material other than glass. The invention could be applied in many ways, including production of an array for an active matrix liquid crystal display (AMLCD). For example, it may be possible to use the invention in producing a scanning array with a thin-film structure or another structure with conductive lines that connect leads of components. AMLCDs in which the invention has been applied have provided good overall performance. An implementation with approximately 6.3 million light control units has performed surprisingly well.

Claims: A method of forming a thin-film structure (16) at a surface (14) of a substrate (12), the method comprising: performing physical vapor deposition to produce a first layer of a molybdenum-chromium alloy; performing lithography to produce a pattern of mask material; the pattern including a part that covers part of the first layer; the covered part of the first layer having the shape of a conductive line (18); and etching to remove areas not covered by the pattern of mask material so that the covered part of the first layer forms a conductive line of a molybdenum-chromium alloy; and removing the part of the pattern of mask material covering the conductive line, wherein that said alloy has from 15 to 85 atomic percent of molybdenum. The method of claim 1, in which the step of performing physical vapor deposition comprises depositing molybdenum and chromium on the surface of the substrate. The method of claim 1 or 2, in which the step of performing physical vapor deposition comprises: sputtering from a molybdenum target; and sputtering from a chromium target. The method of claim 3, in which the step of performing physical vapor deposition comprises: (1) moving the substrate alternately past the molybdenum target and the chromium target to produce alternating sublayers of molybdenum and chromium; the first layer including the alternating sublayers, and/or (2) sputtering from a molybdenum-chromium alloy target. The method of any of the preceding claims, further comprising: performing physical vapor deposition to produce a second layer of a molybdenum-chromium alloy on the first layer; the second layer having a greater atomic ratio of molybdenum to chromium than the first layer so that the second layer has a faster etch rate than the first layer; the act of performing lithography producing the pattern of mask material on the second layer; the act of etching comprising: etching the first and second layers of molybdenum-chromium alloy so that the resulting conductive line is tapered. A structure (10) comprising: a substrate (12) that has a surface (14); and a thin-film structure (16) formed at the surface of the substrate; the thin-film structure comprising: a conductive line (18) of a molybdenum-chromium alloy, wherein that said alloy has from 15 to 85 atomic percent of molybdenum. The structure according to claim 6 including a plurality of said conductive lines, further comprising: an array of light control units for causing presentation of images; each light control unit having a lead for receiving a unit signal; each light control unit capable of responding to its unit signal by causing presentation of a segment of images presented by the array; and wherein each conductive line is connected to a row of the light control units in said array for providing a unit signal to the light control units in that row.

Inventors: ALLEN ROBERT, CHUANG TZU-CHIN, HO JACKSON H, ALLEN, ROBERT, CHUANG, TZU-CHIN, HO, JACKSON H.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1995
Main classification: H01L23
IPC codes: H01L23, G02F1, H01L29, H01L21