Abstract:
An improved and novel fabrication method for a magnetic element, and more particularly a magnetic element ( 10 ) including a first electrode ( 14 ), a second electrode ( 18 ) and a spacer layer ( 16 ). The first electrode (14) includes a fixed ferromagnetic layer ( 26 ) having a thickness t 1 . A second electrode ( 18 ) is included and comprises a free ferromagnetic layer ( 28 ) having a thickness t 2 . A spacer layer ( 16 ) is located between the fixed ferromagnetic layer ( 26 ) and the free ferromagnetic ( 28 ) layer, the spacer layer ( 16 ) having a thickness t 3 , where 0.25t 3 &lt;t 1 &lt;2t 3 , thereby producing near zero magnetic field at the free ferromagnetic layer ( 28 ).

Description:
FIELD OF THE INVENTION 
     The present invention relates to magnetic elements for information storage and/or sensing and a fabricating method thereof, and more particularly, to a method of fabricating and thus defining the magnetic element to improve magnetic field response. 
     BACKGROUND OF THE INVENTION 
     This application is related to a co-pending application that bears U.S. Pat. No. 5,940,319, entitled “MAGNETIC RANDOM ACCESS MEMORY AND FABRICATING METHOD THEREOF,” filed on Aug. 31, 1998, assigned to the same assignee and incorporated herein by this reference, co-pending application that bears U.S. Pat. No. 6,024,885, entitled “PROCESS OF PATTERNING MAGNETIC FILMS” filed on Dec. 8, 1997, assigned to the same assignee and incorporated herein by this reference and issued U.S. Pat. No. 5,768,181, entitled “MAGNETIC DEVICE HAVING MULTI-LAYER WITH INSULATING AND CONDUCTIVE LAYERS”, issued Jun. 16, 1998, assigned to the same assignee and incorporated herein by this reference. 
     Typically, a magnetic element, such as a magnetic memory element, has a structure that includes ferromagnetic layers separated by a non-magnetic layer. Information is stored as directions of magnetization vectors in magnetic layers. Magnetic vectors in one magnetic layer, for instance, are magnetically fixed or pinned, while the magnetization direction of the other magnetic layer is free to switch between the same and opposite directions that are called “Parallel” and “Antiparallel” states, respectively. In response to Parallel and Antiparallel states, the magnetic memory element represents two different resistances. The resistance has minimum and maximum values when the magnetization vectors of the two magnetic layers point in substantially the same and opposite directions, respectively. Accordingly, a detection of changes in resistance allows a device, such as an MRAM device, to provide information stored in the magnetic memory element. The difference between the minimum and maximum resistance values, divided by the minimum resistance is known as the magnetoresistance ratio (MR). 
     An MRAM device integrates magnetic elements, more particularly magnetic memory elements, and other circuits, for example, a control circuit for magnetic memory elements, comparators for detecting states in a magnetic memory element, input/output circuits, etc. These circuits are fabricated in the process of CMOS (complementary metal-oxide semiconductor) technology in order to lower the power consumption of the device. 
     In addition, magnetic elements structurally include very thin layers, some of which are tens of angstroms thick. The performance of the magnetic element is sensitive to the surface conditions on which the magnetic layers are deposited. Accordingly, it is necessary to make a flat surface to prevent the characteristics of a magnetic element from degrading. 
     During typical magnetic element fabrication, such as MRAM element fabrication, which includes metal films grown by sputter deposition, evaporation, or epitaxy techniques, the film surfaces are not absolutely flat but instead exhibit surface or interface waviness. This waviness of the surfaces and/or interfaces of the ferromagnetic layers is the cause of magnetic coupling between the free ferromagnetic layer and the other ferromagnetic layers, such as the fixed layer or pinned layer, which is known as topological coupling or Néel&#39;s orange peel coupling. Such coupling is typically undesirable in magnetic elements because it creates an offset in the response of the free layer to an external magnetic field. 
     The ferromagnetic coupling strength is proportional to surface magnetic charge density and is defined as the inverse of an exponential of the interlayer thickness. As disclosed in U.S. Pat. No. 5,764,567, issued Jun. 9, 1998, and entitled “MAGNETIC TUNNEL JUNCTION DEVICE WITH NONFERROMAGNETIC INTERFACE LAYER FOR IMPROVED MAGNETIC FIELD RESPONSE”, by adding a non-magnetic copper layer next to the aluminum oxide tunnel barrier in a magnetic tunnel junction structure, hence increasing the separation between the magnetic layers, reduced ferromagnetic orange peel coupling, or topological coupling, is achieved. However, the addition of the copper layer will lower the MR of the tunnel junction, and thus degrade device performance. In addition, the inclusion of the copper layer will increase the complexity for etching the material. 
     Accordingly, it is a purpose of the present invention to provide an improved magnetic element with improved field response. 
     It is another purpose of the present invention to provide an improved magnetic element that includes reduced ferromagnetic coupling, more particularly ferromagnetic coupling of topological origin. 
     It is a still further purpose of the present invention to provide a method of forming a magnetic element with improved field response. 
     It is still a further purpose of the present invention to provide a method of forming a magnetic element with improved field response which is amenable to high throughput manufacturing. 
     SUMMARY OF THE INVENTION 
     These needs and others are substantially met through provision of a magnetic element including a first electrode, a second electrode and a spacer layer. The first electrode includes a fixed ferromagnetic layer whose magnetization is fixed in a preferred direction in the presence of an applied magnetic field, the fixed ferromagnetic layer having a thickness t 1 . A second electrode is included and comprises a free ferromagnetic layer whose magnetization is free to rotate in the presence of an applied magnetic field, the free ferromagnetic layer having a thickness t 2 . A spacer layer is located between the fixed ferromagnetic layer of the first electrode and the free ferromagnetic layer of the second electrode for permitting tunneling current in a direction generally perpendicular to the fixed and free ferromagnetic layers, the spacer layer having a thickness t 3 , where 0.25t 3 &lt;t 1 &lt;2t 3 , such that the net magnetic field at the interface between the free layer and the spacer layer, due to the topology of the other ferromagnetic surfaces, is near zero. The magnetic element further includes a metal lead and a substrate, the metal lead, the first and second electrodes and the spacer layer being formed on the substrate. Additionally disclosed is a method of fabricating the magnetic element with improved field response. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIGS. 1 and 2 show cross-sectional views of a magnetic element with improved field response according to the present invention; 
     FIGS. 3-5 illustrate the coupling field with respect to thickness of the metal film layers; 
     FIG. 6 illustrates the creation of magnetic poles by forming interface roughness; 
     FIG. 7 illustrates the magnetic poles created by adjusting the interface roughness of the metal film layers of the magnetic element according to the present invention; and 
     FIG. 8 illustrates the experimental results of the topological coupling field versus the fixed magnetic layer thickness according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     During the course of this description, like numbers are used to identify like elements according to the different figures that illustrate the invention. FIGS. 1 and 2 illustrate in cross-sectional views a magnetic element according to the present invention. More particularly, illustrated in FIG.1, is a fully patterned magnetic element structure  10 . The structure includes a substrate  12 , a base electrode multilayer stack  14 , a spacer layer  16  including oxidized aluminum, and a top electrode multilayer stack  18 . It is additionally disclosed that spacer layer  16  includes either a dielectric material defining a MTJ structure or a conductive material defining a spin valve structure. Base electrode multilayer stack  14  and top electrode multilayer stack  18  include ferromagnetic layers. Base electrode layers  14  are formed on a metal lead  13 , which is formed on a substrate  12 . Base electrode layers  14  include a first seed layer  20 , deposited on metal lead  13 , a template layer  22 , a layer of antiferromagnetic pinning material  24 , and a fixed ferromagnetic layer  26  formed on and exchange coupled with the underlying antiferromagnetic pinning layer  24 . 
     Ferromagnetic layer  26  is described as fixed, or pinned, in that its magnetic moment is prevented from rotation in the presence of an applied magnetic field. Ferromagnetic layer  26  is typically formed of alloys of one or more of the following: nickel (Ni), iron (Fe), and cobalt (Co) and includes a top surface  19  and a bottom surface  21 . Top electrode stack  18  includes a free ferromagnetic layer  28  and a protective layer  30 . The magnetic moment of the free ferromagnetic layer  24  is not fixed, or pinned, by exchange coupling, and is free to rotate in the presence of an applied magnetic field. Free ferromagnetic layer  28  is typically formed of alloys of one or more of the following: nickel (Ni), iron (Fe) and cobalt (Co). Fixed ferromagnetic layer  26  is described as having a thickness of t 1 , wherein t 1  is typically within a range of 5-40 Å. Free ferromagnetic layer  28  is described as having a thickness of t 2 , wherein t 2  is generally less than 50 Å. Spacer layer  16  is described as having a thickness of t 3 , wherein t 3  is generally less than 20 Å for magnetic tunnel junction structures or less than 40 Å for spin valve structures or the like. During fabrication, t 1  is chosen such that the magnetic fields produced by the topology of top surface  19  and bottom surface  21  of fixed ferromagnetic layer  26  cancel to produce near zero coupling energy between free ferromagnetic layer  28  and fixed ferromagnetic layer  26 . It should be understood that a reversed, or flipped, structure is anticipated by this disclosure. More particularly, it is anticipated that the disclosed magnetic element can be formed to include a top fixed, or pinned layer, and thus described as a top pinned structure. 
     Illustrated in FIG.2, is an alternative embodiment of a fully patterned magnetic element structure, referenced  10 ′, including a synthetic antiferromagnetic structure  11 . Again, it should be noted that all components of the first embodiment that are similar to components of the second embodiment, are designated with similar numbers, having a prime added to indicate the different embodiment. Similar to the structure described with regard to FIG. 1, this structure includes a substrate  12 ′, a base electrode multilayer stack  14 ′, a spacer layer  16 ′, and a top electrode multilayer stack  18 ′. Base electrode multilayer stack  14 ′ and top electrode multilayer stack  18 ′ include ferromagnetic layers, generally similar to stack  14  and  18  of FIG.  1 . Base electrode layers  14 ′ are formed on a metal lead  13 ′, which is formed on a substrate  12 ′ and includes a first seed layer  20 ′, deposited on metal lead  13 ′, a template layer  22 ′, a layer of antiferromagnetic material  24 ′, a pinned ferromagnetic layer  23  formed on and exchange coupled with the underlying antiferromagnetic layer  24 ′, a coupling layer  25 , and a fixed ferromagnetic layer  26 ′ which is antiferromagnetically coupled to the pinned layer. Ferromagnetic layer  23  and  26 ′ are described as fixed, or pinned, in that their magnetic moment is prevented from rotation in the presence of an applied magnetic field. Top electrode stack  18  includes a free ferromagnetic layer  28 ′ and a protective layer  30 ′. The magnetic moment of the free ferromagnetic layer  28 ′ is not fixed, or pinned, by exchange coupling, and is free to rotate in the presence of an applied magnetic field. It is disclosed that free ferromagnetic layer  28 ′, includes a Ru antiferromagnetically coupled tri-layer  31  as illustrated in FIG.  2 . 
     Fixed ferromagnetic layer  26 ′ is described as having a thickness of t 1 . Free ferromagnetic layer  28 ′ is described as having a thickness of t 2 . Spacer layer  16 ′ is described as having a thickness of t 3 . It should be understood that a reversed, or flipped, structure is anticipated by this disclosure. More particularly, it is anticipated that the disclosed magnetic element with SAF structure can be formed to include a top fixed, or pinned layer, and thus described as a top pinned structure. 
     Referring now to FIG. 3, a diagrammatic illustration is provided showing the effect of the thickness of the free ferromagnetic layer, such as layer  28  of FIG. 1, and the relative coupling field of the magnetic element. Magnetic elements typically utilized in information storage and/or sensing devices necessitate the use of thin free layers to maintain low switching fields. Yet, as illustrated in FIG. 3, when designing devices with these thin free layers, the coupling field H cpl  is increased. The coupling field as illustrated increases as 1/d free  where d is the thickness of the free layer such as  28  or  28 ′. Accordingly, to lower the coupling field H cpl , adjustments can be made in the remaining structure of the magnetic element as disclosed herein. 
     Referring to FIG. 4, illustrated is the reduction in the coupling field H cpl  by adjusting the thickness of the fixed layer, such as layer  26  of FIG.  1 . As illustrated, by decreasing the thickness of the fixed layer, the coupling field H cpl  is decreased, approaching near zero. Accordingly, and as illustrated in FIG. 5, a magnetic element, generally similar to magnetic element  10  of FIG. 1, having included in addition to free layer  18 , a fixed layer having a thickness of 15 Å will provide for a dramatic lowering shift in the Hcpl curve, hence the ability to achieve near zero coupling. 
     In addition, as illustrated in FIG. 6, by adjusting the roughness of the interface of the pinning layer in a structure such as that disclosed as magnetic element  10  of FIG. 1, a decrease in the magnetic field response coupling can be achieved. Referring more specifically to FIG. 6, h 3  is the waviness amplitude of an interface surface  25  of AF pinning layer  24  most remote from free layer  28 , h 2  is the waviness amplitude of an interface surface  27  of fixed ferromagnetic layer  26 , closest to free ferromagnetic layer  28 , and h 1  is the waviness amplitude of an interface surface  29  of spacer layer  16 , closest to free ferromagnetic layer  28 . Magnetic poles are created by the interface roughness, hn, with period λ. Interface surface  27  of fixed layer  26  couples positively to interface surface  29  of free layer  28 . Interface surface  25  of AF pinning layer  24  couples negatively to interface surface  29  of free layer  28 . The Hcpl depends on h 3 /h 2 , the thickness of fixed layer  26  and the λ. By increasing the roughness of h 3  so that h 3 &gt;h 2 , near zero coupling can be further achieved in magnetic element  10 . More specifically, when h 3 &gt;h 2 , there will be one point with respect to the thickness of fixed layer  26 , where the field response coupling will exactly cancel the magneto-static coupling which is zero at d fixed =0. 
     The roughness of interface  25 , or h 3 , can be adjusted by increasing or decreasing the thickness of pinning material  24 , ion bombardment, or deposition of a third material. More specifically, the roughness of pinning material  24  can be increased or decreased by making pinning material  24  thinner or thicker, wherein, fixed layer  26  must “heal” the roughness to result in h 3 &gt;h 2 . Typically nickel iron (NiFe) will result in proper “healing” to result in h 3 &gt;h 2 . Utilizing an alternative method to adjust the roughness of interface surface  25 , ion bombardment is utilized to either roughen pinning material  24  or smooth surface  27  of pinned material  26 . Finally, the adjustment of roughness can be achieved by depositing a small amount of a third material between pinning layer  24  and fixed layer  26  to increase h 3 , particularly if the material grows with an island-like structure. 
     Next, it is disclosed that the use of non-magnetic seed and template layers ( 20  and  22 ) will result in a decrease in the magnetic field response coupling without the need for the inclusion of a SAF structure. The template layer will add no moment to the structure, thus the only magneto-static coupling is a result of the thin pinned layer included within the structure. Accordingly, adjustments can be made for the canceling of the level of coupling to achieve near zero coupling. When template layer  22  is nonmagnetic, and there is no SAF, negative magnetostatic coupling due to poles at the ends of the patterned shape and positive Neel coupling controlled by the thickness of pinned layer  24 . The thickness of pinned layer  24  could be chosen to offset the magnetostatic coupling giving a centered loop. 
     Finally, it is disclosed to include a high moment alloy, such as Ni(50%)Fe(50%) on at least one side of fixed ferromagnetic layer  26  to increase the negative coupling contribution to the total coupling effect. 
     Referring now to FIG. 7, illustrated is the structure of magnetic element  10 ′ of FIG. 2 showing the magnetic poles created. During operation of magnetic element  10 ′ as disclosed herein, when the total magnetic field from the poles at the interfaces other than the one at the origin of the y axis is near zero, then the topological coupling will be near zero. When the total field at the y axis origin is negative, then the topological coupling will be negative or antiferromagnetic in nature. Usually the total field at the y axis origin where the free magnetic layer lies is positive, thus causing ferromagnetic topological coupling. However, for the structure shown in FIG. 7, for certain conditions, particularly when the fixed layer thickness is thin, topological coupling can be zero or even negative. 
     The additional interface will produce an even stronger cancellation of the coupling from interface  27  than could be accomplished by interface  25  alone. Experimental results of the topological coupling field versus the fixed magnetic layer thickness are shown in FIG.  8 . As the fixed magnetic layer thickness decreases in the magnetic tunnel junction structure, the coupling field decreases, crosses zero, and finally becomes negative. Overall the layers in magnetic memory element  10  are very thin with magnetic layers varying from 3 to 200 Å. 
     Thus, a magnetic element with an improved field response and its fabrication method are disclosed in which the magnetic coupling is adjusted based on the thickness of the fixed ferromagnetic layer, and/or roughness of the interface surface of the fixed ferromagnetic layer relative to the remaining metal thin film structure. As disclosed, this technique can be applied to devices using patterned magnetic elements, such as magnetic sensors, magnetic recording heads, magnetic recording media, or the like. Accordingly, such instances are intended to be covered by this disclosure