Abstract:
A manufacturing method of a semiconductor device having a highly reliable capacitor, and the semiconductor device are provided. The semiconductor device manufacturing method according to the present invention includes: a first step of forming a first electrode of a capacitor on a semiconductor substrate; a second step of forming a capacitor insulating film on the whole surface including a side surface and an upper surface of the first electrode; a third step of forming a protection insulating film made of a material different from that of the capacitor insulating film, on the capacitor insulating film; a fourth step of removing the protection insulating film and the capacitor insulating film from the upper surface of the first electrode, by anisotropically etching the protection insulating film and the capacitor insulating film; a fifth step of removing the protection insulating film that remains on the side surface of the first electrode; and a sixth step of forming a second electrode of the capacitor on the capacitor insulating film, after removing the protection insulating film.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a semiconductor device manufacturing method and a semiconductor device. Particularly, the invention relates to a semiconductor device having a stacked capacitor, and a method of manufacturing the semiconductor device. 
       BACKGROUND OF THE INVENTION 
       [0002]    Conventionally, in a DRAM (Dynamic Random Access Memory) having a stacked capacitor, in order to compensate for a decrease of electrostatic capacitance due to a reduction in the size of the capacitor, the height of the capacitor has been increased or a high dielectric material has been used for a capacitor insulating film. 
         [0003]    However, when the size of the capacitor further decreases in future, the above measure is not sufficient, and the configuration of the capacitor needs to be more complex. When the capacitor has a more complex configuration, a process of processing the capacitor insulating film becomes additionally necessary. For example, when a capacitor configuration in which plural capacitor layers are laminated is considered, in order to secure a connection between an upper electrode of a lower layer and an upper electrode of an upper layer and between a lower electrode of the lower layer and a lower electrode of the upper layer, respectively, it becomes necessary to perform etch back or the like on the capacitor insulating film, thereby exposing a connection part between the upper and the lower electrodes. When the capacitor insulating film is to be etched, the following problems occur. 
         [0004]      FIG. 13A  to  FIG. 13C  show processes of forming one capacitor layer of a capacitor having the laminated configuration. 
         [0005]    First, as shown in  FIG. 13A , an electrode film is formed on a ground interlayer insulating film  200 . This electrode film is patterned to form a lower electrode  201 . A capacitor insulating film  202  is formed on the whole surface including a side surface and an upper surface of the lower electrode  201 . Next, the capacitor insulating film  202  is anisotropically etched, or etched back on the whole surface, to leave the capacitor insulating film on only the side wall of the lower electrode  201 , as shown in  FIG. 13B . As a result, the capacitor insulating film on the upper surface of the lower electrode  201  is removed. With this arrangement, a lower electrode (not shown) of the next capacitor layer to be formed on this capacitor layer can be connected to the lower electrode  201 , on the exposed upper surface of the lower electrode  201 . 
         [0006]    However, due to this etch back process, an adhesion X of an etching damage, a residual molecule of an etching product, or the like occurs on the surface of the capacitor insulating film  202 . This etching damage, the residual molecule, or the like increases a leakage of current between an upper electrode  203  and the lower electrode  201  as shown by an arrowhead A in  FIG. 13C , thereby decreasing reliability of the capacitor. 
         [0007]    At a lower end of the capacitor insulating film  202 , there is an interface with the interlayer insulating film  200 , and a connection of atom level is disconnected. Further, due to the etch back, the capacitor insulating film becomes locally thin. Consequently, leakage current occurs easily at the lower end of the capacitor insulating film  202 , as shown by an arrowhead B in  FIG. 13C . 
         [0008]    Semiconductor devices having the stacked capacitors are described in, for example, Japanese Patent Application Laid-open Nos. 2000-332213, H05-267614, H11-345948, 2004-111711, and 2001-24169. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention has been achieved to solve the above problems. It is an object of the present invention to provide a manufacturing method of a semiconductor device having a highly reliable capacitor, which suppresses an etching damage on a capacitor insulating film of the capacitor and suppress occurrence of leakage current, and the semiconductor device. 
         [0010]    It is another object of the invention to provide a semiconductor device that can suppress the occurrence of leakage current at the lower end of a capacitor insulating film of a capacitor, and a method of manufacturing this semiconductor device. 
         [0011]    The semiconductor device manufacturing method according to the present invention includes: a first step of forming a first electrode of a capacitor on a semiconductor substrate; a second step of forming a capacitor insulating film on the whole surface including a side surface and an upper surface of the first electrode; a third step of forming a protection insulating film made of a material different from that of the capacitor insulating film, on the capacitor insulating film; a fourth step of removing the protection insulating film and the capacitor insulating film from the upper surface of the first electrode, by anisotropically etching the protection insulating film and the capacitor insulating film; a fifth step of removing the protection insulating film that remains on the side surface of the first electrode; and a sixth step of forming a second electrode of the capacitor on the capacitor insulating film, after removing the protection insulating film. 
         [0012]    According to the semiconductor device manufacturing method of the present invention, the surface of the capacitor insulating film is protected by the protection insulating film, at the time of performing anisotropic etching of the capacitor insulating film. Therefore, an etching damage or a residual molecule of an etching product occurs on only the surface of the protection insulating film. Since the protection insulating film is removed after the etching, a damaged layer and a residual molecule of the protection insulating film can be completely removed. Therefore, the surface of the capacitor insulating film can be kept clean. Consequently, increase in the leakage current of the capacitor and reduction in reliability can be prevented. 
         [0013]    Further, after performing the anisotropic etching, a part of the capacitor insulating film that extends in a direction of a second electrode is formed in a width corresponding to the film thickness of the protection insulating film, at a lower end of the capacitor insulating film. Accordingly, the occurrence of leakage current between a first electrode and a second electrode at the lower end of the capacitor insulating film can be suppressed. 
         [0014]    The semiconductor device includes a capacitor according to the present invention comprising: a first electrode provided on a semiconductor substrate; a capacitor insulating film provided on a side surface of the first electrode; and a second electrode provided on a surface of the capacitor insulating film facing the first electrode, wherein the capacitor insulating film has a first part along the side surface of the first electrode, and a second part extending substantially in parallel with the semiconductor substrate from a lower end of the first part in a direction of the second electrode. 
         [0015]    According to the semiconductor device of the present invention, presence of the second part at the lower end of the capacitor insulating film can suppress the occurrence of leakage current between the first electrode and the second electrode at the lower end of the capacitor insulating film. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The above and other objects, features and advantages of the present invention will become more apparent by reference to the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein: 
           [0017]      FIG. 1  is a partial cross-sectional diagram showing one step (formation of an element isolation region  101  to contact plugs  109 ) in a method of manufacturing a semiconductor device according to an embodiment of the present invention; 
           [0018]      FIG. 2  is a partial cross-sectional diagram showing one step (formation of a conductive film  110  and a silicon nitride film  111 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0019]      FIG. 3  is a partial cross-sectional diagram showing one step (patterning of the conductive film  110  and the silicon nitride film  111 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0020]      FIG. 4  is a partial cross-sectional diagram showing one step (formation of a tantalum oxide film  115  and a silicon oxide film  116 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0021]      FIG. 5  is a partial cross-sectional diagram showing one step (etching back of the silicon oxide film  116  and the tantalum oxide film  115 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0022]      FIG. 6  is a partial cross-sectional diagram showing one step (formation of a silicon oxide film  117 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0023]      FIG. 7  is a partial cross-sectional diagram showing one step (selectively removing of the silicon oxide films  117  and  116 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0024]      FIG. 8  is a partial cross-sectional diagram showing one step (formation of a tungsten film  118 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0025]      FIG. 9  is a partial cross-sectional diagram showing one step (polishing of the tungsten film  118  by the CMP method) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0026]      FIG. 10  is a partial cross-sectional diagram showing one step (formation of an interlayer insulating film  120  to formation of an interlayer insulating film  123 ) in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0027]      FIG. 11A  to  FIG. 11D  are partially enlarged views of a lower end periphery L of the plate electrode  113  in the processes shown in  FIGS. 4 ,  5 ,  7 , and  9 , respectively, in the method of manufacturing the semiconductor device according to the embodiment of the present invention; 
           [0028]      FIG. 12  is a cross-sectional diagram of the DRAM when there are four capacitor layers in the embodiment of the present invention; and 
           [0029]      FIG. 13A  to  FIG. 13C  are processes of forming one capacitor layer of a capacitor having the laminated configuration. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0030]    An exemplary embodiment of a semiconductor device manufacturing method according to the present invention will be explained below with reference to the accompanying drawings. The present invention is adopted in a DRAM in the embodiment. 
         [0031]      FIG. 1  to  FIG. 10  are partial cross-sectional diagrams showing a process of manufacturing the DRAM according to the present embodiment. 
         [0032]    First, as shown in  FIG. 1 , an element isolation region  101  consisting of a silicon oxide film is formed on a semiconductor substrate  100  by an STI (Shallow Trench Isolation) method, and then, memory cell transistors are formed. In  FIG. 1 , a gate electrode is not shown, because the diagram shows a cross section along an extension direction of a word line. Diffusion layers  102 , each of which is one of two diffusion layers (source/drain layers) of each memory cell transistor, are shown in  FIG. 1 . 
         [0033]    Next, an interlayer insulating film  103  is formed on the whole surface, and thereafter, contact plugs  104  that are respectively connected to the diffusion layers  102  are formed. Polysilicon can be used for a material of the contact plugs  104 . Next, an interlayer insulating film  105  is formed on the whole surface, and then, contact plugs (not shown) to be respectively connected to bit lines and the contact plugs  104  or the other diffusion layers are formed. Thereafter, a tungsten film is formed on the whole surface, and the tungsten film is patterned to form bit lines  106 . 
         [0034]    Next, a silicon oxide film  107  and a silicon nitride film  108  are formed on the whole surface, and contact plugs  109  are formed. The contact plugs  109  are formed to be respectively connected to the contact plugs  104 . A laminated film of Ti/TiN and tungsten (W) can be used for a material of the contact plugs  109 . The configuration as shown in  FIG. 1  is obtained through the above process. 
         [0035]    Next, as shown in  FIG. 2 , a conductive film  110  having a thickness of about 900 nm and a silicon nitride film  111  having a thickness of about 200 nm are formed in this order on the whole surface. The conductive film  110  is a laminated film of a Ti/TiN film  110   a  having a thickness of about 20/30 nm, an AlCu film  110   b  having a thickness of about 800 nm, and a TiN film  110   c  having a thickness of about 50 nm, in this order. The silicon nitride film  111  is patterned using a mask (not shown), according to a lithographic technique, thereby forming a cap insulating film  112  as shown in  FIG. 3 . The conductive film  110  (see  FIG. 2 ) is patterned to form a plate electrode  113 , which is used as a common plate electrode for a plurality of capacitors. The plate electrode  113  is formed to avoid plural contact plugs  109 . Accordingly, the upper surfaces of the contact plugs  109  are exposed by through-holes  114 . When etching control is poor at the time of patterning the conductive film  110  (i.e., at the time of forming the plate electrode  113 ) and when the contact plugs  109  at the bottom of the through-holes  114  collapse greatly, it is preferable to form a stopper insulating film in advance on the contact plugs  109 . The plate electrode  113  is one large electrode that is provided in common to plural memory cell transistors. Although the plate electrode  113  is divided in the cross-sectional diagram shown in  FIG. 3 , this is continuous in other cross section. 
         [0036]    Next, as shown in  FIG. 4 , a tantalum oxide (Ta 2 O 5 ) film  115  having a thickness of about 5 nm that becomes a capacitor insulating film of the capacitor is formed on the whole surface by an ALD (Atomic Layer Deposition) method, without removing the cap insulating film  112 . A silicon oxide film  116  having a thickness of about 5 nm is formed as a protection insulating film on the tantalum oxide film  115 . As a result, the surfaces of the plate electrode  113  and the contact plug  109  are covered with the tantalum oxide film  115  and the silicon oxide film  116 . 
         [0037]    Next, as shown in  FIG. 5 , anisotropic etching is performed on the silicon oxide film  116 , and then on the tantalum oxide film  115 . The anisotropic etching can be performed on the whole surface of the silicon oxide film  116  and the tantalum oxide film  115 , respectively, without using a mask. As a result, the silicon oxide film  116  and the tantalum oxide film  115  that are formed in a region parallel with the semiconductor substrate  100  can be removed. Consequently, the upper surfaces of the contact plugs  109  are exposed at the bottom of the through-holes  114 . On the other hand, the silicon oxide film  116  and the tantalum oxide film  115  that are formed in a region substantially perpendicular to the semiconductor substrate  100  are not removed. Consequently, the tantalum oxide film  115  and the silicon oxide film  116  remain on the side surface of the plate electrode  113  and on the inner side surface of the through-holes  114 . 
         [0038]    While an etching damage and an etching product adhere to the surface of the silicon oxide film  116  in the anisotropic etching (etch back) process, the silicon oxide film  116  becomes the etching protection film. Therefore, adhesion of an etching damage or an etching product to the tantalum oxide film (capacitor insulating film)  115  beneath the silicon oxide film  116  can be prevented. 
         [0039]    Next, as shown in  FIG. 6 , a silicon oxide film  117  with a large thickness is formed on the whole surface so as to fill the through-holes  114 . Thereafter, the silicon oxide film  117  is flattened by a CMP (Chemical Mechanical Polishing) method. While  FIG. 6  shows a state that the silicon oxide film  117  remains on the cap insulating film  112 , when control according to the CMP method is sufficient, the cap insulating film  112  can be exposed as a stopper film according to the CMP method. 
         [0040]    Next, as shown in  FIG. 7 , regions other than where the through-holes  114  are formed are covered with a mask layer (not shown), and wet etching is performed using hydrofluoric acid or the like, thereby selectively removing the silicon oxide film  117  and the silicon oxide film (protection insulating film)  116  within the through-holes  114 . As a result, the upper surfaces of the contact plugs  109  are exposed again on the bottom surfaces of the through-holes  114 . The protection insulating film  116  that received the etching damage and the like by the last etch back process is removed by this wet etching, and the capacitor insulating film  115  that has not received the etching damage is exposed. 
         [0041]    As shown in  FIG. 8 , a tungsten film  118  is formed on the whole surface so as to fill the through-holes  114 . 
         [0042]    Next, the tungsten film  118  and the silicon oxide film  117  are polished by the CMP method, using the cap insulating film  112  as a stopper. In this process, storage electrodes  119  of the capacitors filled in the through-holes  114  are obtained as shown in  FIG. 9 . As a result, capacitor layer  10  consisting of the storage electrodes  119 , the tantalum oxide films (capacitor insulating films)  115 , and the plate electrode  113  is formed. 
         [0043]    Next, as shown in  FIG. 10 , an interlayer insulating film  120  is formed on the capacitor layer  10 , and a contact plug  121  to be connected to the plate electrode  113  of the capacitor layer  10  is formed. Further, a laminated film of a TiN/Ti film  122   a , an AlCu film  122   b , and a TiN film  122   c  is formed on the interlayer insulating film  120 . The laminated film is patterned to form a wiring layer  122 . Thereafter, an insulating film  123  that covers the wiring layer  122  is formed. Further, wiring connection plugs and upper layer wirings (not shown) are formed by a necessary number of layers. Last, a protection film is generated on the top wiring layer, and a connection hole is formed on the protection film to expose an electrode pad, thereby completing a DRAM. 
         [0044]    Advantageous effects of the embodiment will be explained in detail below. 
         [0045]      FIG. 11A  to  FIG. 11D  show partially enlarged views of a lower end periphery L of the plate electrode  113  in the processes shown in  FIGS. 4 ,  5 ,  7 , and  9 , respectively. While the plate electrode  113  is a laminated film, this plate electrode  113  is shown as a single layer in  FIG. 11A  to  FIG. 11D , for the sake of convenience. 
         [0046]    As shown in  FIG. 11A  (corresponding to  FIG. 4 ), the capacitor insulating film (tantalum oxide film)  115  and the protection insulating film (silicon oxide film)  116  are laminated on the whole side surface (inner side surface of the through-hole  114 ) of the patterned plate electrode  113  to cover this side surface. The whole surface is then etched back. As a result, as shown in  FIG. 11B  (corresponding to  FIG. 5 ), the protection insulating film  116  and the capacitor insulating film  115  on the base silicon nitride film  108  (the bottom portion of the through-hole  114 ) are removed. In this case, an adhesion X of an etching damage, a residual molecule of the etching product, or the like occurs on the surface of the protection insulating film  116 . However, the adhesion X of the etching damage or the like does not reach the surface of the capacitor insulating film  115 . Thereafter, the protection insulating film  116  including the adhesion X of the etching damage or the like is removed. As a result, as shown in  FIG. 11C  (corresponding to  FIG. 7 ), only the good-quality capacitor insulating film  115  having no etching damage or the like remains on the side surface of the plate electrode  113 . The silicon oxide film  116  as a protection insulating film can be removed by wet etching using hydrofluoric acid. Since the tantalum oxide film  115  as the capacitor insulating film has high etching resistance against hydrofluoric acid and the like, the tantalum oxide film  115  is little damaged in the process of removing the silicon oxide film  116 . 
         [0047]    Accordingly, as shown in  FIG. 11D  (corresponding to  FIG. 9 ), when the storage electrode  119  is formed on the capacitor insulating film  115  having a clean surface, occurrence of leakage current in the capacitor can be suppressed, and a highly reliable capacitor can be obtained. 
         [0048]    In the present embodiment, after the protection insulating film  116  is formed on the capacitor insulating film  115 , the protection insulating film  116  and the capacitor insulating film  115  are etched back. With this arrangement, as shown in  FIG. 11B  to  FIG. 11D , after ending the etch back process, the capacitor insulating film  115  has a substantially vertical part V along the side surface of the plate electrode  113 , and a horizontal part H that extends substantially parallel with the semiconductor substrate in the direction of the storage electrode  119  from the lower end of the vertical part V. Owing to the presence of the horizontal part H, a distance between the plate electrode  113  and the storage electrode  119  is secured at the lower end of the capacitor insulating film  115 . Consequently, occurrence of leakage current can be suppressed. The length of the horizontal part H substantially corresponds to the thickness of the protection insulating film  116 . Therefore, the length can be adjusted by suitably changing the thickness of the protection insulating film  116 . 
         [0049]    In the present, embodiment, as shown in  FIG. 4 , the cap insulating film is formed on the plate electrode  113 , and the capacitor insulating film  115  and the protection insulating film  116  are formed on this cap insulating film. This has the following effects. 
         [0050]    When anisotropic etching (etch back) process is performed after the capacitor insulating film  115  and the protection insulating film  116  are formed as shown in  FIG. 4 , a film thickness at the upper end of the capacitor insulating film  115  becomes smaller than that of other parts as shown in  FIG. 5 . However, in the present embodiment, at the end of the anisotropic etching, the upper end of the capacitor insulating film  115  is kept within the film thickness of the cap insulating film  112 . In other words, anisotropic etching is controlled so that the capacitor insulating film  115  covers at least a part of the side surface of the cap insulating film  112  at the end of the etching. Accordingly, the side surface of the plate electrode  113  can be covered with the capacitor insulating film  115  having a sufficient thickness, up to the upper end of the plate electrode  113 . As a result, as shown in  FIG. 9 , the upper end of each of the capacitor insulating films  115  does not become thin at the upper end of the plate electrode  113  of the capacitor layer  10 , and increase in leakage current can be suppressed. 
         [0051]    A pattern formed by lithography is usually narrower than a desired pattern. However, in the present embodiment, the plate electrode is formed before the storage electrodes by lithography. Therefore, even when the pattern of the plate electrode is narrower than the desired pattern, the surface area of the storage electrode formed thereafter is not made smaller, and is rather increased. In other words, even when the pattern shape of the plate electrode varies due to the variation in the lithography condition, this variation works to increase the electrostatic capacity, as compared with a storage electrode of island-shape pattern which is independently formed beforehand as in the conventional process. Therefore, a possibility of a capacity shortage can be reduced. 
         [0052]    In the present embodiment, plural capacitor layers having the same shape as that of the capacitor layer  10  can be also laminated, by repeating plural times substantially the same process as shown in  FIG. 2  to formation of the contact plug  121  in  FIG. 10 , after forming the interlayer insulating film  120  and the contact plug  121  shown in  FIG. 10 .  FIG. 12  shows one example of this configuration.  FIG. 12  shows a configuration of a DRAM obtained by laminating four capacitor layers  10   a  to  10   d . Plate electrodes  113   a  to  113   d  of the capacitor layers are electrically connected by contact plugs  121   a  to  121   c , and are connected to a higher wiring layer  122  by a contact plug  121   d . Storage electrodes  119   a  to  119   d  of the capacitor layers are connected vertically, and are electrically connected to the diffusion layers  102  provided on the semiconductor substrate, respectively. By laminating the plural capacitor layers, a large electrostatic capacitance can be obtained. According to the present embodiment, even when such a complex capacitor configuration is adopted, leakage current can be suppressed, and a capacitor having high reliability can be obtained. 
         [0053]    While preferred embodiments of the present invention have been described hereinbefore, the present invention is not limited to the aforementioned embodiments and various modifications can be made without departing from the spirit of the present invention. It goes without saying that such modifications are included in the scope of the present invention. 
         [0054]    While, as an example, the plate electrode is formed first and then the storage electrode is formed in the above embodiment, the present invention is not limited to this particular process. Alternatively, the storage electrode can be formed first, and then, the plate electrode can be formed. When the plate electrode is formed first in the present invention, the above effect can be obtained. 
         [0055]    While a laminated film of a Ti/TiN film, an AlCu film, and a TiN film is used for the plate electrode in the above embodiment, other conductive materials such as a tungsten film may be used instead. Materials of other insulating films and wirings can be also suitably changed. 
         [0056]    An aluminum oxide film or an hafnium oxide film, or a laminated film of these films can be used, instead of the tantalum oxide film, for the material of the capacitor insulating film. 
         [0057]    According to the present invention, anisotropic etching is performed after a protection insulating film is formed on a capacitor insulating film. Therefore, the occurrence of an etching damage on the surface of the capacitor insulating film can be prevented. 
         [0058]    Further, a part of the capacitor insulating film extending in a lateral direction corresponding to a film thickness of the protection insulating film is formed at a lower end of the capacitor insulating film. Therefore, the occurrence of leakage current of a capacitor at the lower end of the capacitor insulating film can be suppressed.