Source: http://www.google.com/patents/US20020168868?dq=5,666,293
Timestamp: 2016-08-27 17:07:19
Document Index: 651894574

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

Patent US20020168868 - Deposition Over Mixed Substrates - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsAbstract of Disclosure Chemical vapor deposition methods are used to deposit silicon-containing films over mixed substrates. Such methods are useful in semiconductor manufacturing to provide a variety of advantages, including uniform deposition over heterogeneous surfaces, high deposition rates, and...http://www.google.com/patents/US20020168868?utm_source=gb-gplus-sharePatent US20020168868 - Deposition Over Mixed SubstratesAdvanced Patent SearchPublication numberUS20020168868 A1Publication typeApplicationApplication numberUS 10/074,633Publication dateNov 14, 2002Filing dateFeb 11, 2002Priority dateFeb 12, 2001Also published asDE60223662D1, DE60223662T2, DE60227350D1, EP1374290A2, EP1374290B1, EP1374291A2, EP1374291B1, EP1421607A2, US6716713, US6716751, US6743738, US6821825, US6900115, US6958253, US6962859, US7186582, US7273799, US7285500, US7547615, US7585752, US7893433, US8067297, US8360001, US20020173113, US20020197831, US20030022528, US20030068851, US20030068869, US20030082300, US20050048745, US20050064684, US20050208740, US20050250302, US20070102790, US20080014725, US20080073645, US20100012030, WO2002064853A2, WO2002064853A3, WO2002065508A2, WO2002065508A3, WO2002065516A2, WO2002065516A3, WO2002065516A8, WO2002065517A2, WO2002065517A3, WO2002080244A2, WO2002080244A3, WO2002080244A9Publication number074633, 10074633, US 2002/0168868 A1, US 2002/168868 A1, US 20020168868 A1, US 20020168868A1, US 2002168868 A1, US 2002168868A1, US-A1-20020168868, US-A1-2002168868, US2002/0168868A1, US2002/168868A1, US20020168868 A1, US20020168868A1, US2002168868 A1, US2002168868A1InventorsMichael ToddOriginal AssigneeTodd Michael A.Export CitationBiBTeX, EndNote, RefManPatent Citations (48), Referenced by (160), Classifications (124), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetDeposition Over Mixed Substrates
US 20020168868 A1Abstract
[0001] This application claims priority to U.S. Provisional Application No. 60/268,337, filed February 12, 2001; U.S. Provisional Application No. 60/279,256, filed March 27, 2001; U.S. Provisional Application No. 60/311,609, filed August 9, 2001; U.S. Provisional Application No. 60/323,649, filed September 19, 2001; U.S. Provisional Application No. 60/332,696, filed November 13, 2001; U.S. Provisional Application No. 60/333,724, filed November 28, 2001; and U.S. Provisional Application No. 60/340,454, filed December 7, 2001; all of which are hereby incorporated by reference in their entireties. This application is also related to, and incorporates by reference in their entireties, co-owned and co-pending U.S. Patent Application Serial Numbers: 10/074,563; 10/074,149; 10/074,722; 10/074,564; and 10/074,534, all of which were filed on February 11, 2002.
[0002] This application relates generally to the deposition of silicon-containing materials, and more particularly to chemical vapor deposition of silicon-containing films over mixed substrates.
[0003] A variety of methods are used in the semiconductor manufacturing industry to deposit materials onto surfaces. For example, one of the most widely used methods is chemical vapor deposition (CVD), in which atoms or molecules contained in a vapor deposit on a surface and build up to form a film. Deposition of silicon-containing (Si-containing) materials using conventional silicon sources and deposition methods is believed to proceed in several distinct stages, see Peter Van Zant, Microchip Fabrication, 4th Ed., McGraw Hill, New York, (2000), pp. 364-365. Nucleation, the first stage, is very important and is greatly affected by the nature and quality of the substrate surface. Nucleation occurs as the first few atoms or molecules deposit onto the surface and form nuclei. During the second stage, the isolated nuclei form small islands that grow into larger islands. In the third stage, the growing islands begin coalescing into a continuous film. At this point, the film typically has a thickness of a few hundred angstroms and is known as a transition film. It generally has chemical and physical properties that are different from the thicker bulk film that begins to grow after the transition film is formed. [0004] Deposition processes are usually designed to produce a particular type of bulk film morphology, e.g., epitaxial, polycrystalline or amorphous. When using conventional silicon sources and deposition processes, nucleation is very important and critically dependent on substrate quality. For example, attempting to grow a single-crystal film on a wafer with islands of unremoved oxide will result in regions of polysilicon in the bulk film. Because of these nucleation issues, deposition of thin film Si-containing materials with similar physical properties onto substrates having two or more different types of surfaces using conventional silicon sources and deposition methods is often problematic. [0005] For example, silicon tetrachloride (SiCl4), silane (SiH4), and dichlorosilane (SiH2Cl2) are the most widely used silicon sources in the semiconductor manufacturing industry for depositing Si-containing films, see Peter Van Zant, Microchip Fabrication, 4th Ed., McGraw Hill, New York, (2000), p 380-382. However, deposition using these conventional silicon sources is generally difficult to control over mixed substrates, such as surfaces containing both single crystal silicon and silicon dioxide. Control is difficult because the morphology and thickness of the resulting Si-containing film depend on both the deposition temperature and the morphology of the underlying substrate. Other deposition parameters, including total reactor pressure, reactant partial pressure and reactant flow rate can also strongly influence the quality of depositions over mixed substrates.
[0009] However, additional process steps are generally undesirable because they may increase expense, contamination and/or complication. The ability to deposit satisfactory mixed morphology Si-containing films over mixed substrates would satisfy a long-felt need and represent a significant advance in the art of semiconductor manufacturing. Summary of Invention
[0010] Methods have now been discovered that utilize trisilane to deposit high quality Si-containing films over a variety of substrates. In accordance with one aspect of the invention, a deposition method is provided, comprising:providing a substrate disposed within a chamber, wherein the substrate comprises a first surface having a first surface morphology and a second surface having a second surface morphology different from the first surface morphology;introducing trisilane to the chamber under chemical vapor deposition conditions; anddepositing a Si-containing film onto the substrate over both of the first surface and the second surface.
[0015] [0015]Figure 1A to 1C are schematic cross sections illustrating problems encountered in prior art deposition methods onto a mixed substrate.
[0017] [0017]Figure 3A to 3C of the invention illustrates deposition over a mixed substrate, including a window between field oxide regions, using trisilane in accordance with a preferred embodiment.
[0018] [0018]Figure 4 illustrates a SiGe base structure for a BiCMOS HBT, constructed in accordance with a preferred embodiment.
[0020] [0020]FIGURE 6 is a reproduction of a scanning electron photomicrograph illustrating a SiGe film deposited using silane and germane.
[0021] [0021]FIGURE 7 is a reproduction of a scanning electron photomicrograph illustrating a cross section of the SiGe film shown in Figure 6.
[0022] [0022]FIGURE 8 is a reproduction of a scanning electron photomicrograph showing a SiGe film deposited using trisilane and germane, in accordance with a preferred embodiment.
[0023] [0023]FIGURE 9 is a reproduction of a scanning electron photomicrograph showing a cross section of the SiGe film shown in Figure 8.
[0024] Deposition processes have now been discovered that are much less sensitive to nucleation phenomena. These processes employ trisilane (H3SiSiH2SiH3) to enable the deposition of high quality Si-containing films over mixed substrates. Figure 2A schematically illustrates a preferred structure 200 resulting from such a deposition process. Compared to Figure 1B, successful deposition of a Si-containing film 210 over both types of substrate surface (the single crystal, semiconductor surface 220 and the dielectric surface 230) while maintaining epitaxial crystal quality and a close match in total deposited thickness can be achieved using trisilane. Figures 2A and 2B are described in more detail below.
[0031] A suitable manifold may be used to supply feed gas(es) to the CVD chamber. In the illustrated embodiments, the gas flow in the CVD chamber is horizontal, most preferably the chamber is a single-wafer, single pass, laminar horizontal gas flow reactor, preferably radiantly heated. Suitable reactors of this type are commercially available, and preferred models include the Epsilon™series of single wafer reactors commercially available from ASM America, Inc. of Phoenix, Arizona. While the methods described herein can also be employed in alternative reactors, such as a showerhead arrangement, benefits in increased uniformity and deposition rates have been found particularly effective in the horizontal, single-pass laminar gas flow arrangement of the Epsilon™chambers, employing a rotating substrate, particularly with low process gas residence times. CVD may be conducted by introducing plasma products (in situ or downstream of a remote plasma generator) to the chamber, but thermal CVD is preferred.
[0034] The amount of dopant precursor in the feed gas may be adjusted to provide the desired level of dopant in the Si-containing film. Typical concentrations in the feed gas can be in the range of about 1 part per billion (ppb) to about 1% by weight based on total feed gas weight, although higher or lower amounts are sometimes preferred in order to achieve the desired property in the resulting film. In the preferred Epsilon™ series of single wafer reactors, dilute mixtures of dopant precursor in a carrier gas can be delivered to the reactor via a mass flow controller with set points ranging from about 10 to about 200 standard cubic centimeters per minute (sccm), depending on desired dopant concentration and dopant gas concentration. The dilute mixture is preferably further diluted by mixing with trisilane and any suitable carrier gas. Since typical total flow rates for deposition in the preferred Epsilon™series reactors often range from about 20 standard liters per minute (slm) to about 180 slm, the concentration of the dopant precursor used in such a method is small relative to total flow.
[0065] The processes of the preferred embodiments involve the use of trisilane to deposit a Si-containing film over both surfaces of a mixed substrate in a single step, thus eliminating masking, etching, and separate deposition steps of Figure 5 to be more like the process flow of Figure 4. The structure shown in Figure 3B is illustrative of the preferred embodiments and may be produced in a single step by modifying the process flow illustrated in Figure 5. This modification is preferably practiced by replacing a silicon source such as silane with trisilane and depositing the Si-containing film over both surfaces in a single step as illustrated in Figure 3. Example 1
[0066] A substrate was provided consisting of a 1500 �SiO2 (oxide) coating deposited onto a Si(100) wafer. The substrate was patterned to remove about 20% of the oxide coating to expose the underlying Si(100) wafer, thus creating a mixed substrate having a single-crystal surface and an amorphous oxide surface. The mixed substrate was then etched in a solution of dilute hydrofluoric acid, rinsed and dried. The mixed substrate was then loaded into an Epsilon E2500™reactor system and subjected to a hydrogen bake at 900�C at atmospheric pressure under a flow of 80 slm of ultra-pure hydrogen for 2 minutes. The mixed substrate was then allowed to reach thermal equilibrium at 600�C at 40 Torr pressure under a flow of 20 slm of ultra-pure hydrogen gas. The steps of etching, drying, rinsing, and baking rendered the single crystal surface active for epitaxial film growth.
[0071] A Si-containing film was deposited onto a SiO2 substrate (without a nucleation layer) at a temperature of 600�C using silane and germane as precursors. The surface roughness of the resulting SiGe film (as measured by atomic force microscopy) was 226 �for a 10 micron �10 micron scan area. Scanning electron microscopy (SEM) of the SiGe film revealed pyramidal, faceted grains indicative of an island-type deposition, as demonstrated in the SEM micrographs shown in Figures 6 and 7. This island-type deposition shows that deposition proceeded by a process in which isolated nuclei first formed on the surface, then grew together to form the islands shown. This illustrates the sensitivity of deposition to surface morphology when silane is used, i.e., poor nucleation of silane-deposited layers on oxide and consequent roughness. Example 3
[0072] A Si-containing film was deposited at 600�C as described in Example 2, but trisilane and germane were used in place of silane and germane as precursors. The surface roughness of the resulting SiGe film (as measured by atomic force microscopy) was 18.4 �for a 10 micron x 10 micron scan area. SEM of the SiGe film revealed a much more uniform surface, as demonstrated in the SEM micrographs shown in Figures 8 and 9 (same magnifications and tilt angles as Figures 6 and 7, respectively). The relative lack of island-type deposition, as compared to silane, shows that deposition occurred evenly over the surface, and did not proceed by the nucleation and growth mechanism described above in Example 2. This illustrates the relative insensitivity of deposition to surface morphology when trisilane is used, i.e., excellent nucleation of trisilane-deposited layers and consequent smoothness.
[0073] A series of Si-containing films were deposited onto a SiO2 substrate (without a nucleation layer) at a pressure of 40 torr using trisilane and germane. The trisilane flow rate was constant at 77 sccm (hydrogen carrier, bubbler) for the examples of Table 1. Germane flow (10% germane, 90% H2) and deposition temperature were varied as shown in Table 1. Germanium concentration (atomic %) and thickness of the resulting SiGe films were determined by RBS, and surface roughness was determined by atomic force microscopy (AFM). The results shown in Table 1 demonstrate that highly uniform films can be prepared over a range of temperatures and flow rate conditions, particularly over a range of germane concentration, and further illustrate the relative insensitivity of deposition to surface morphology when trisilane is used. TABLE 1 Deposition Temp. Germane Thickness Rate Roughness No. (� C.) Flow (sccm) % Ge (Å) (Å/min) (Å) 1 450 25 5.0 34* 8.5 3.2 2 450 50 7.5 34* 11 4.1 3 450 100 11 59* 15 3.7 4 450 100 11 53* 13 nd 5 500 25 6.0 190 63 7.8 6 500 50 10 230 77 9.1 7 500 100 13.5 290 97 8.3 8 500 100 13.5 380* 127 7.2 9 550 25 6.0 630 315 5.2 10 550 50 9.5 670 335 13.6 11 550 100 14 900 450 12.1 12 550 100 14 1016 508 9.4 13 600 25 7.0 1160 580 8.1 14 600 50 13 1230 615 25.7 15 600 100 19 1685 843 31.8 16 650 25 11 630 630 23.3 17 650 50 17 800 800 31.5 18 650 100 27 1050 1050 50.2 19 700 25 11 680 680 18.1 20 700 50 18 835 835 37.8 21 700 100 31 960 960 44.9 [0074] [0074]
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doped crystalline si-layers by cvdWO2012002994A1 *Jun 23, 2011Jan 5, 2012International Business Machines CorporationSelective epitaxy of si-containing materials and substitutionally doped crystalline si-containing materials* Cited by examinerClassifications U.S. Classification438/767, 257/E21.101, 257/E21.197, 257/E21.119, 257/E21.102, 257/E21.17, 257/E29.162, 257/E21.166, 438/933, 257/E21.131International ClassificationH01L29/737, H01L21/469, H01L21/8238, H01L21/331, H01L21/337, H01L29/78, C23C16/42, H01L21/316, H01L27/092, H01L21/425, H01L21/28, C23C16/24, H01L31/18, C23C16/02, H01L29/51, H01L31/20, H01L21/285, H01L21/205, C30B25/02, H01L21/20Cooperative ClassificationY02P70/521, B82Y30/00, Y10S438/933, Y02E10/547, C23C16/308, C30B25/02, H01L31/202, H01L29/518, H01L29/66242, H01L29/51, H01L21/28556, C23C16/56, H01L21/02667, H01L21/0262, H01L21/02595, H01L21/3185, H01L21/28044, B82Y10/00, H01L29/127, C23C16/325, H01L29/517, H01L31/1804, H01L21/02576, H01L29/66181, H01L21/02529, H01L21/02592, H01L21/28194, Y02E10/546, H01L21/28035, C30B29/06, C23C16/345, H01L21/32055, H01L21/2257, H01L21/0243, C23C16/30, H01L31/182, H01L21/0245, C23C16/24, H01L21/02422, H01L21/02579, C23C16/36, H01L28/84, H01L21/0251, H01L21/02598, H01L21/28525, C23C16/22, H01L21/02532, C23C16/0272European ClassificationC23C16/30, H01L29/12W4, C23C16/56, C23C16/36, H01L21/225A4F, H01L21/318B, C23C16/24, C23C16/34C, C23C16/32B, C30B25/02, C23C16/30E, C23C16/22, H01L21/3205N, H01L21/28E2C2D, H01L29/51M, C30B29/06, H01L21/28E2B2P, H01L21/02K4C1A3, H01L21/02K4C3C1, H01L21/02K4C5M2, H01L21/02K4E3C, H01L21/02K4A1K, H01L21/02K4C3C2, H01L21/02K4B1A3, H01L21/02K4B5L7, H01L21/02K4C1A2, H01L21/02K4C5M1, H01L21/02K4C5M3, H01L21/02K4A5S, B82Y30/00, B82Y10/00, H01L28/84, H01L29/66M6D6, H01L29/66M6T2H, H01L31/20B, H01L21/20B, H01L21/285B4H, C23C16/02H, H01L29/51, H01L31/18C5, H01L21/20C, H01L21/28E2B2, H01L21/205, H01L21/205B, H01L31/18C, H01L21/285B4BLegal EventsDateCodeEventDescriptionMay 23, 2002ASAssignmentOwner name: ASM AMERICA, INC., ARIZONAFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:TODD, MICHAEL A.;REEL/FRAME:012909/0607Effective date: 20020422Dec 5, 2006CCCertificate of correctionDec 8, 2008REMIMaintenance fee reminder mailedMay 11, 2009FPAYFee paymentYear of fee payment: 4May 11, 2009SULPSurcharge for late paymentSep 28, 2012FPAYFee paymentYear of fee payment: 8RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services