Source: http://www.google.com/patents/US5855970?dq=No.+6,411,949&ei=AUR7T-LGJqSr0AHy2aSiBg
Timestamp: 2015-04-02 10:23:00
Document Index: 719619293

Matched Legal Cases: ['art 35', 'art 35', 'art 35', 'art 7', 'art 7', 'art 7', 'art 2', 'art 2']

Patent US5855970 - Chemical vapor deposition - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAn improved CVD apparatus for depositing a uniform film is shown. The apparatus comprises a reaction chamber, a substrate holder and a plurality of light sources for photo CVD or a pair of electrodes for plasma CVD. The substrate holder is a cylindrical cart which is encircled by the light sources, and...http://www.google.com/patents/US5855970?utm_source=gb-gplus-sharePatent US5855970 - Chemical vapor depositionAdvanced Patent SearchPublication numberUS5855970 APublication typeGrantApplication numberUS 08/769,115Publication dateJan 5, 1999Filing dateDec 18, 1996Priority dateSep 9, 1986Fee statusLapsedAlso published asUS5427824, US5629245Publication number08769115, 769115, US 5855970 A, US 5855970A, US-A-5855970, US5855970 A, US5855970AInventorsTakashi Inushima, Shigenori Hayashi, Toru Takayama, Masakazu Odaka, Naoki HiroseOriginal AssigneeSemiconductor Energy Laboratory Co., Ltd.Export CitationBiBTeX, EndNote, RefManPatent Citations (89), Non-Patent Citations (35), Referenced by (12), Classifications (51), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetChemical vapor deposition
US 5855970 AAbstract
1. A method for forming a film on a substrate comprising the steps of:preparing a substrate having an uneven upper surface in a reaction chamber; forming a layer comprising silicon oxide on said uneven upper surface by plasma CVD using a reactive gas comprising at least organic silane and nitrogen oxide in said reaction chamber; and cleaning an inside of said reaction chamber by plasma cleaning. 2. The method of claim 1 further comprising the step of removing an upper portion of said layer.
3. The method of claim 1 wherein said organic silane is TEOS.
4. The method of claim 1 wherein said nitrogen oxide is N2 O.
5. A method for forming a film comprising the steps of:preparing a substrate having an uneven upper surface provided with aluminum leads thereon; forming a layer comprising silicon oxide on said uneven upper surface by plasma CVD using a reactive gas comprising at least organic silane and nitrogen oxide. 6. The method of claim 5 further comprising the step of removing an upper portion of said layer.
7. The method of claim 5 wherein said organic silane is TEOS.
8. The method of claim 5 wherein said nitrogen oxide is N2 O.
9. A method of forming a film comprising the steps of:preparing a substrate having an uneven surface; forming a first layer comprising a material selected from the group consisting of silicon oxide and silicon nitride by CVD; forming a second layer comprising silicon oxide by plasma CVD using a reactive gas containing at least organic silane and nitrogen oxide. 10. The method of claim 9 wherein said organic silane is TEOS.
11. The method of claim 9 wherein said nitrogen oxide is N2 O.
12. The method of claim 9 wherein said first layer is formed by using a reactive gas comprising SiH4 or Si2 H6.
13. A method for forming a device comprising the steps of:preparing a substrate having an uneven upper surface; forming a first layer comprising a material selected from the group consisting of silicon oxide and silicon nitride on said uneven upper surface by CVD using a first reactive gas comprising a carbon free silicon containing material; and forming a second layer comprising silicon oxide on said first layer by plasma CVD using a second reactive gas comprising at least organic silane. 14. The method of claim 13 wherein said carbon free silicon containing material is selected from the group consisting of SiH4 and Si2 H6.
15. The method of claim 13 wherein said organic silane is TEOS.
16. A method for forming a device comprising the steps of:preparing a substrate having an uneven upper surface provided with aluminum leads thereon; forming a first layer comprising a material selected from the group consisting of silicon oxide and silicon nitride on said uneven upper surface by CVD using a first reactive gas comprising a carbon free silicon containing material; and forming a second layer comprising silicon oxide on said first layer by plasma CVD using a second reactive gas comprising at least organic silane. 17. The method of claim 16 further comprising the step of etching a surface of said second layer.
18. The method of claim 16 wherein said carbon free silicon containing material is selected from the group consisting of SiH4 and Si2 H6.
19. The method of claim 16 wherein said organic silane is TEOS.
20. A method for forming a device comprising the steps of:preparing a substrate having an uneven upper surface provided with a first lead comprising aluminum; forming a first layer comprising a material selected from the group consisting of silicon oxide and silicon nitride on said uneven upper surface by CVD using a carbon free silicon compound gas; forming a second layer comprising silicon oxide on said first layer by plasma CVD using a reactive gas containing at least organic silane; removing an upper portion of said second layer to obtain a smoother surface; and then forming a second lead comprising aluminum on said second layer. 21. The method of claim 20 wherein said reactive gas further contains nitrogen oxide.
22. The method of claim 20 wherein said carbon free silicon containing material is selected from the group consisting of SiH4 and Si2 H6.
23. The method of claim 20 wherein said organic silane is TEOS.
This is a Divisional application of Ser. No. 08/376,736 filed Jan. 23, 1995, U.S. Pat. No. 5,629,245, which itself is a division of Ser. No. 07/971,242 filed Sep. 8, 1992, U.S. Pat. No. 5,427,824, which is a continuation of Ser. No. 07/702,492 filed May 20, 1991, abandoned; which is a continuation-in-part of Ser. No. 07/497,794 filed Mar. 22, 1990, abandoned; which is a continuation of Ser. No. 07/091,770 filed Sep. 1, 1987, abandoned.
Hg+hv&#8594;&gt;Hg* ("*" is a symbol for excitation) Hg* +SiH4 &#8594;SiH3 +H-+Hg ("-" is a symbol for radical) Hg*+NH3 &#8594;NH2 --+H--+Hg yNH2 --+xSiH3 &#8594;Six Ny +zH2 In the above equations, x, y and z are chosen appropriately.
FIG. 1 is a cross-section view showing a photo CVD apparatus which has been devised by the inventors in advance of the present invention. To facilitate the understanding of the background of the present invention, this apparatus will be briefly explained. In the figure, the apparatus comprises a reaction chamber 31, light source chambers 39 and ultraviolet light sources 41. Between the light source chambers 39, a cart 35 is mounted so as to be capable of moving in the direction perpendicular to the drawing sheet. The cart is provided with heaters 37 to heat substrates mounted on the external surfaces of the cart 35 facing to the light source chambers 39. The temperature of the substrates 33 is elevated to about 200� C. which is suitable for forming a silicon nitride film. In the reaction chamber 31 is circulated a process gas at a pressure of several Torrs. The process gas is irradiated through quartz windows 47 with light radiated from the light source 41. A numeral 45 designates electrodes by virtue of which discharge takes place with the cart as the other electrode and undesired product deposited on the surface of the quartz windows 47 can be eliminated by sputtering.
However, with this apparatus, the thickness of deposited film depends on th spatial relationship between the light sources and the position of the substrates. Namely, the product of the CVD process may be deposited with a greater thickness at the position irradiated with stronger light. Generally speaking, the tolerable fluctuation of the thickness of the film is about 10. Furthermore, the quartz windows 47 have to be thick to bear the differential pressure between the inside of the reaction chamber 31 and the light source chamber 39 in which cooling gas is circulated. The differential pressure may cause leakage of the cooling gas from the light source chamber 39 into the reaction chamber 31. As an alternative, a particular cooling system may be provided for the light source chamber so the pressure in the light source chamber, and therefore the differential pressure, can be decreased. Also, when discharge between the cart 35 and the reaction chamber 31 is desired to remove unnecessary film deposited on the light window by sputtering, the discharge tends to deviate from the window. Because of this, the particular electrodes 45 have to be provided which makes the size of the apparatus large.
FIGS. 5(A), 5(B) and 5(C) are graphical diagrams showing the distributions of the intensity on substrates mounted on prism-shaped substrate holder having cross-sections of regular polygons of 6, 12, and 24 sides.
FIGS. 6(A), 6(B) and 6(C) and FIG. 7 are section views showing the process of an example of CVD in accordance with this invention.
Next, the process in the apparatus will be explained. First, twelve substrates are mounted on the cart 7 and entered into the reaction chamber 3. After evacuating the reaction chamber 3 to 10-2 -10-6 Torr by means of the exhaustion system 13, a process gas is inputted from the introduction system 11 at about 3 Torr. Simultaneously, the substrates 15 are heated by the heater 23 to about 200� C. Then, the cart 7 encircled by the mercury lamps 19 is rotated at 2 rpm by the driving device 9 and irradiated with ultraviolet light from the lamps 19, whereupon the product of a reaction initiated by optical energy is deposited on the substrates 15. The product undesirably deposited on the quartz tubes 17 can be removed by sputtering in virtue of discharge between the cart 7 and the reaction chamber 3. Photo enhanced CVD process is carried out, e.g., in accordance with the following equation:
3Si2 H6 +8NH3 &#8594;2Si3 N4 +21H2 or SiH4 +4N2 O&#8594;SiO2 +4N2 +2H2 O (1)
SiO4 (C2 H5)4 +1402 &#8594;SiO2 +8CO2 +10H2 O, or SiO4 (C2 H5)4 +28N2 O&#8594;SiO2 +8CO2 +10H2 O+28N2      (2)
Si3 N4 +4NF3 &#8594;3SiF4 +4N2 3SiO2 +4NF3 &#8594;3SiF4 +2N2 +303 To investigate the relationship between the uniformity of the illumination intensity on the substrate and the number of side faces of the cart, experimental data has been gathered. FIGS. 5(A) to 5(C) are graphical diagrams showing the distributions of the intensity on substrates mounted on prism-shaped substrate holders having cross-sections of regular polygons of 6, 12 and 24 sides. In the figure, the abscissa is the distance of the measuring point from the center of a substrate, and the ordinate is the intensity normalized with reference to the maximum intensity measured on the substrate. As shown from the diagrams, the distribution of the intensity becomes more uniform as the number of the faces increases. Namely, the intensity fluctuates over the irradiated surface at larger than 10% in the case of the cart having six faces, while the fluctuation of the intensity is limited within 5% in the cases of the carts having twelve and twenty-four faces. The cart having twenty-four faces may hold forty-eight substrate by mounting two substrates on each face.
FIGS. 6(A), 6(B) and 6(C) are cross-section views showing an example of CVD process in accordance with the present invention. The surface of a substrate to be coated is provided with a plurality of aluminum lead lines 51. The leads 51 are elongated in the direction perpendicular to the drawing sheet with 0.8 micron in height, 0.6 micron in width and 0.9 micron in interval as shown in FIG. 6(A). A silicon oxide film is deposited on the substrate over the leads 51 by photo CVD in accordance with the equation (1) to the thickness of 0.3 to 0.5 at about 400� C. as shown in FIG. 6(B). Further, another silicon oxide film 55 is deposited by plasma CVD in accordance with the equation (2) at 200� C. as shown in FIG. 6(C).
The use of TEOS is advantageous particularly for forming a film on an uneven surface, specifically, it is possible to form a substantially even or uniform film, even on a side surface of or on a lower surface between the steps shown in FIG. 6(A) by reference numeral 51. It is presumed that this is because TEOS is in a liquid state at room temperature and has a relatively large viscosity even when it is gasified. The even upper surface is desirable when provided with an overlying aluminum electrode 57 as shown in FIG. 7. The likelihood of disconnection of electrode 57 is reduced by the even surface. After the completion of the deposition, the inside of the reaction chamber on the mercury lamp 19, only one being schematically shown in FIGS. 6(A), 6(B) and 6(C). The etching process can be implemented on the deposited film before or after plasma CVD in order to obtain even surface of the film or to chamfer the edge of the film deposited.
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