Abstract:
Contacts having use in an integrated circuit and exemplary methods of forming the contacts are disclosed. The methods involve forming a conductive cap over a metal plug. The invention can mitigate keyholes in the contacts by capping and encapsulating the conductive material used to form the contact. The exemplary cap may be made of a nitride material.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to the field of semiconductor devices and, in particular, to the formation of contacts for memory and other integrated circuit devices. 
       BACKGROUND OF THE INVENTION 
       [0002]    A well known semiconductor memory component is random access memory (RAM). RAM permits repeated read and write operations on its memory elements. Typically, RAM devices are volatile, in that stored data is lost once the power source is disconnected or removed. Examples of RAM devices include dynamic random access memory (DRAM), synchronous dynamic random access memory (SDRAM) and static random access memory (SRAM). In addition, DRAMS and SDRAMS also typically store data in capacitors, which require periodic refreshing to maintain the stored data. 
         [0003]    Recently, resistance variable memory elements, which include programmable conductor random access memory (PCRAM) elements employing a chalcogenide material, have been investigated for suitability as semi-volatile and non-volatile random access memory devices. One such PCRAM device is disclosed in U.S. Pat. No. 6,348,365, assigned to Micron Technology Inc. and incorporated herein by reference. In typical PCRAM devices, conductive material, such as silver, is moved within the chalcogenide material to alter the cell resistance. Thus, the resistance of the chalcogenide material can be programmed to stable higher resistance and lower resistance states. The programmed lower resistance state can remain intact for a long period, typically ranging from hours to weeks, after the voltage potentials are removed. 
         [0004]    One aspect of fabricating resistance variable memory cells, which also occurs in fabrication of other integrated circuit devices, involves contacts used for connecting the memory cells to integrated circuitry formed several layers beneath the cells. Oftentimes, because of the high aspect ratio of long vias, contacts provided therein have either sharp corners, keyholes or both, created during the contact formation. The sharp corners are created by the long, vertical sidewalls of the vias. During plug formation in vias having high aspect ratios, CVD is incapable of filling the vias completely before the plug is closed, resulting in keyhole defects in the plugs. Subsequent chemical mechanical polishing or etchback fabrication steps can expose the key and are to create a completely smooth via topography. Additionally, cell material can fall into the keyholes during deposition, leading to a non-uniform cell surface, or worse, a cracks or breaks in the cell surface, which can cause the cell to malfunction, and effectively limits the materials that can be used in the memory cell. 
         [0005]    The sharp corners and/or keyholes may also result in inconsistent and unreliable switching of the memory device. Put another way, these problems make the cell unable to reliably switch between high and low resistance states. Such problems also reduce memory device yield and the lifetime of a memory cell is potentially cut short. Therefore, it is important in the fabrication of integrated circuit contacts, including those employing resistance variable memory cells, to create a smooth-surfaced or faceted conductive plugs on which subsequent material may be deposited. 
         [0006]    Referring to  FIG. 1 , a cross sectional view of a portion of a conventional memory device  100  is shown. A dielectric layer  110  contains metal plugs  120  which connect to lower structures of the memory device  100 . For purposes of clarity, only one plug  120  is shown. For a resistance variable memory, cell material  140  is formed over the dielectric  110  and plugs  120 . As discussed above, however, keyholes  130  in the metal plugs  120  can prevent smooth deposition of the cell material  140  and cause interference with the operation of the memory cell  100 . Keyholes  130  are very difficult to avoid when employing conventional methods of forming metal plugs  120 , such as chemical vapor deposition (“CVD”). 
         [0007]    Accordingly, there is a need for conductive contacts mitigate against formation of keyhole defects. There is also a need and desire for conductive contacts for use in a resistance variable memory device that compensate for keyhole and other defects. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    Exemplary embodiments of the invention provide contacts having smooth edges for use in an integrated circuit. Exemplary methods of forming the contacts are also disclosed. The methods involve forming a conductive cap over a metal plug, which encapsulates the conductive material used to form the contact. The exemplary cap may be made of a conductive nitride material. 
         [0009]    In accordance with one exemplary embodiment, the integrated circuit is a resistance variable memory device. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0010]    The above-discussed and other features and advantages of the invention will be better understood from the following detailed description, which is provided in connection with the accompanying drawings, in which: 
           [0011]      FIG. 1  is a cross-sectional view of a portion of a conventional memory device; 
           [0012]      FIG. 2  is a cross-sectional view of a portion of an exemplary memory device constructed in accordance with the invention; 
           [0013]      FIG. 3  is a cross-sectional view of a portion of the exemplary memory device of  FIG. 2  during a stage of fabrication; 
           [0014]      FIG. 4  is a cross-sectional view of a portion of the exemplary memory device of  FIG. 2  during a stage of fabrication subsequent to that shown in  FIG. 3 ; 
           [0015]      FIG. 5  is a cross-sectional view of a portion of the exemplary memory device of  FIG. 2  during a stage of fabrication subsequent to that shown in  FIG. 4 ; 
           [0016]      FIG. 6(   a ) is a cross-sectional view of a portion of the exemplary memory device of  FIG. 2  during a stage of fabrication subsequent to that shown in  FIG. 5 ; 
           [0017]      FIG. 6(   b ) is an isometric view of a portion of another exemplary memory device during a stage of fabrication subsequent to that shown in  FIG. 5 ; 
           [0018]      FIG. 7  is a cross-sectional view of a portion of the exemplary memory device of  FIG. 2  during a stage of fabrication subsequent to that shown in  FIG. 6 ; 
           [0019]      FIG. 8  is a cross-sectional view of a portion of the exemplary memory device during a stage of fabrication subsequent to that shown in  FIG. 7 ; and 
           [0020]      FIG. 9  illustrates a computer system having a memory element in accordance with the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    In the following detailed description, reference is made to various specific embodiments of the invention. These embodiments are described with sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other embodiments may be employed, and that various structural, logical and electrical changes may be made without departing from the spirit or scope of the invention. 
         [0022]    The term “substrate” used in the following description may include any supporting structure including, but not limited to, a semiconductor substrate that has an exposed substrate surface. A semiconductor substrate should be understood to include silicon, silicon-on-insulator (SOI), silicon-on-sapphire (SOS), doped and undoped semiconductors, epitaxial layers of silicon supported by a base semiconductor foundation, and other semiconductor structures. When reference is made to a semiconductor substrate or wafer in the following description, previous process steps may have been utilized to form regions or junctions in or over the base semiconductor or foundation. The substrate need not be semiconductor-based, but may be any support structure suitable for supporting an integrated circuit. 
         [0023]    The term “resistance variable memory element” is intended to include any memory element that exhibits and holds a resistance change in response to an applied voltage. 
         [0024]    The invention is now explained with reference to the figures, which illustrate exemplary embodiments and where like reference numbers indicate like features. It should be understood that the portions shown are illustrative of one embodiment of the invention, and that the invention encompasses other memory and non-memory integrated circuit devices that can be formed using different materials and processes than those described herein. 
         [0025]      FIG. 2  shows a portion of an array of memory elements which includes a memory cell  200  constructed in accordance with the invention. A dielectric layer  210 , formed over a substrate (not shown), contains metal plugs  220  that serve as bottom electrodes for memory device  200 . For purposes of clarity, only one plug  240  is illustrated. Conductive cap  250  is formed over the metal plugs  220 , covering and fitting keyholes  230  and isolating keyholes  230  from cell material  240 . Resistance variable cell material  240  is formed over the dielectric  210  and cap  250 . As shown in  FIG. 2 , the cap  250  completely cover and encapsulate keyhole defects  230 , thereby preventing the irregularities in the cell material  240  that occur in the cell material  140  of prior art memory cell  100 . It should be understood that cell material  240  will comprise a plurality of layers of materials used in the formation of variable resistance memory cells. Without limiting the invention, exemplary cell layers and materials are described in U.S. Pat. No. 6,849,868 to Campbell, which is incorporated herein by reference. 
         [0026]    Referring now to  FIGS. 3-8 , exemplary method steps for forming the exemplary cap  250  in accordance with the invention are now described. It should be understood that the description of the materials and fabrication steps are illustrative only. 
         [0027]    Turning to  FIG. 3 , metal plugs  220  are formed within dielectric layer  210  by any known process. In accordance with a preferred embodiment, the metal plugs  220  are tungsten and are formed using CVD, but other metals or conductive materials may also be used. Conventional CVD steps may leave keyhole defects  230  in the plugs  220 . 
         [0028]    Referring to  FIG. 4 , a conductive material layer for forming the cap  250  is blanket deposited over the dielectric  210 , plugs  220  and keyholes  230 . The conductive material layer is then planarized by any known process, for example, by chemical mechanical polishing (CMP). This step may also be performed by selectively depositing the material over and around the individual plugs  220 . In accordance with a preferred embodiment of the invention, the conductive material is a tungsten alloy, such as, e.g., Ti/TiN/W or TiN/W, which may be deposited by physical vapor deposition (PVD) or by other known processes. 
         [0029]    Next, as shown in  FIG. 5 , the conductive material for forming the cap  250  is coated with a photoresist layer  260 . As shown in  FIG. 6(   a ), the conductive material for the cap is then etched using conventional patterning techniques to form individual caps  250  over respective plugs  220 . These conventional techniques include known dry or wet etch methods compatible with the conductive material of the cap  250 . Other exemplary embodiments include etching the cap  250  to include faceted sides  253 , as shown in  FIG. 6(   b ). The faceted sides  253  of cap  250  provide smooth contact points and have a lower fabrication cost compared to rounded caps. The photoresist  260  is then removed, as illustrated by  FIG. 7 , leaving conductive cap  250  exposed. 
         [0030]    With reference to  FIG. 8 , exemplary methods of completing the memory device  200  will now be described. Cell material  240  is deposited over the array. The cell material  240  may include resistance variable cell material, like the materials necessary for construction of PCRAM memory cells constructed according to the teachings of U.S. Pub. Appl. Nos. 2003/0155589 and 2003/0045054, each assigned to Micron Technology Inc., and incorporated herein by reference. Appropriate cell materials include layers of germanium selenide and silver-containing layers. The memory device  200  will also include a plurality of upper electrodes (not shown), each formed over the cell material  240  and over each bottom electrode  220 ,  250 , defining the memory cell as the portion of the cell material  240  therebetween. 
         [0031]    The embodiments described above refer to the formation of a memory device  200  structure in accordance with the invention. It must be understood, however, that the invention contemplates the formation of other integrated circuit elements, and the invention is not limited to use with memory devices. Moreover, although described as a single memory device  200 , the device  200  can be fabricated as a part of a memory array and operated with memory element access circuits. 
         [0032]      FIG. 9  is a block diagram of a processor-based system  1200 , which includes a memory circuit  1248 , for example a resistance variable memory device circuit employing non-volatile memory devices  200  ( FIG. 2 ) fabricated in accordance with the invention. The processor system  1200 , such as a computer system, generally comprises a central processing unit (CPU)  1244 , such as a microprocessor, a digital signal processor, or other programmable digital logic devices, which communicates with an input/output (I/O) device  1246  over a bus  1252 . The memory circuit  1248  communicates with the system over bus  1252  typically through a memory controller. 
         [0033]    In the case of a computer system, the processor system may include peripheral devices such as a floppy disk drive  1254  and a compact disc (CD) ROM drive  1256 , which also communicate with CPU  1244  over the bus  1252 . Memory  1248  is preferably constructed as an integrated circuit, which includes one or more resistance variable memory devices  200 . If desired, the memory  1248  may be combined with the processor, for example CPU  1244 , in a single integrated circuit. 
         [0034]    The above description and drawings are only to be considered illustrative of exemplary embodiments which achieve the features and advantages of the invention. Modification and substitutions to specific process conditions and structures can be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be considered as being limited by the foregoing description and drawings, but is only limited by the scope of the appended claims.