Patent ID: 7459396

Claim:
A method of depositing a Ru metal layer on a patterned substrate, comprising: providing a patterned substrate in a process chamber of a deposition system, wherein the patterned substrate contains one or more vias or trenches, or combinations thereof; forming a process gas containing Ru 3 (CO) 12 precursor vapor and a carrier gas comprising CO gas by: providing a solid Ru 3 (CO) 12 precursor in a plurality of spaced trays within a precursor evaporation system, wherein each tray in the plurality of spaced trays is configured to support the solid Ru 3 (CO) 12 precursor and wherein the plurality of spaced trays collectively provide a plurality of surfaces of solid Ru 3 (CO) 12 precursor; heating the solid Ru 3 (CO) 12 precursor in the plurality of spaced trays in the precursor evaporation system to a temperature greater than about 60° C. and maintaining the solid Ru 3 (CO) 12 precursor at the temperature to form the Ru 3 (CO) 12 precursor vapor; and flowing the carrier gas in contact with the plurality of surfaces of the solid Ru 3 (CO) 12 precursor in the precursor evaporation system during the heating to capture Ru 3 (CO) 12 precursor vapor in the carrier gas as the vapor is being formed at the plurality of surfaces; transporting the process gas from the precursor evaporation system to the process chamber; and exposing the patterned substrate to the process gas to deposit a Ru metal layer on the patterned substrate by a thermal chemical vapor deposition process.