Patent Document

This is a division of application Ser. No. 10/734,201 filed Dec. 15, 2003, which is a division of application Ser. No. 10/022,721 filed Dec. 20, 2001, which issued as U.S. Pat. No. 6,743,641 on Jun. 1, 2004, the entireties of which are incorporated herein by reference. 

   FIELD OF INVENTION 
   The present invention relates to a magnetic random access memory (MRAM) and a fabricating method thereof, and more particularly to a method of improving surface planarity prior to bit material deposition. 
   BACKGROUND OF THE INVENTION 
   Magnetic random access memories (MRAMs) employ magnetic multilayer films as storage elements. When in use, an MRAM cell stores information as digital bits, which in turn depend on the alternative states of magnetization of thin magnetic multilayer films forming each memory cell. As such, the MRAM cell has two stable magnetic configurations, high resistance representing a logic state 0 and low resistance representing a logic state 1, or vice versa. 
   A typical multilayer-film MRAM includes a number of bit or digit lines intersected by a number of word lines. At each intersection, a film of a magnetically coercive material is interposed between the corresponding bit line and word line. Thus, this magnetic material and the multilayer films from the digit lines form a magnetic memory cell which stores a bit of information. 
   The basic memory element of an MRAM is a patterned structure of a multilayer material, which is typically composed of a stack of different materials, such as copper (Cu), tantalum (Ta), permalloy (NiFe) or aluminum oxide (Al 2 O 3 ), among others. The stack may contain as many as ten different overlapping material layers and the layer sequence may repeat up to ten times. Fabrication of such stacks requires deposition of the thin materials layer by layer, according to a predefined order. 
     FIG. 1  shows an exemplary conventional MRAM structure including MRAM stacks  22  which have three respective associated bit or digit lines  18 . The digit lines  18 , typically formed of copper (Cu), are first formed in an insulating layer  16  formed over underlayers  14  of an integrated circuit (IC) substrate  10 . Underlayers  14  may include, for example, portions of integrated circuitry, such as CMOS circuitry. A pinned layer  20 , typically formed of ferromagnetic materials, is provided over each digit line  18 . A pinned layer is called “pinned” because its magnetization direction does not change during operation of the memory device. A sense layer  21  is provided over each associated pinned layer  20 . The MRAM stacks  22  are coupled to a word line  23  that intersects three pinned layers  20  and associated sense layers  21 . The word line  23  and bit line  18  may also be interchanged. 
   An MRAM device integrates magnetic memory elements and other circuits, for example, a control circuit for magnetic memory elements, comparators for detecting states in a magnetic memory element, input/output circuits, etc. These circuits are fabricated in the process of CMOS technology in order to lower the power consumption of the MRAM device. The CMOS process requires high temperature steps which exceeds 300° C. for depositing dielectric and metal layers and annealing implants, for example. 
   In addition, a magnetic memory element includes very thin layers, some of them are tens of angstroms thick. The performance of the magnetic memory element is sensitive to the surface conditions on which magnetic layers are deposited. Accordingly, it is necessary to form a flat surface at certain stages of fabrication to prevent the characteristics of an MRAM device from degrading. The present invention provides a method of fabricating an MRAM having a more planar surface prior to deposition of the magnetic stack. 
   SUMMARY OF THE INVENTION 
   The present invention provides a method of improving surface planarity prior to bit material deposition in MRAM structures. In an exemplary embodiment of the invention, a first conductor in a trench is provided in an insulating layer and an upper surface of the insulating layer and the first conductor is planarized. This leaves a roughened upper surface on the conductor. Further, a material layer is formed over the planarized upper surface of the insulating layer and the first conductor and an upper portion of the material layer is again planarized or flattened while leaving intact a lower portion of the material layer over the insulating layer and the first conductor. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above advantages and features of the invention will be more clearly understood from the following detailed description which is provided in connection with the accompanying drawings. 
       FIG. 1  is a schematic three-dimensional view of a portion of a conventional MRAM structure; 
       FIG. 2  illustrates a partial cross-sectional view of a semiconductor topography, at an intermediate stage of the processing, wherein a MRAM will be constructed in accordance with the present invention; 
       FIG. 3  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 2 ; 
       FIG. 4  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 3 ; 
       FIG. 5  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 4 ; 
       FIG. 6  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 5 ; 
       FIG. 7  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 6 ; 
       FIG. 8  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 7 ; 
       FIG. 9  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 8 ; 
       FIG. 10  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 9 ; 
       FIG. 11  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 10 ; 
       FIG. 12  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 11 ; 
       FIG. 13  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 12 ; 
       FIG. 14  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 13 ; 
       FIG. 15  illustrates a partial cross-sectional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 14 ; 
       FIG. 16  is a partial three-dimensional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 15 ; 
       FIG. 17  is a partial three-dimensional view of the MRAM of the present invention at a stage of processing subsequent to that shown in  FIG. 16 ; 
       FIG. 18  is a partial three-dimensional view of the MRAM of  FIG. 17  at a stage of processing subsequent to that shown in  FIG. 17 ; 
       FIG. 19  is a partial three-dimensional view of the MRAM of  FIG. 17  at a stage of processing subsequent to that shown in  FIG. 18 ; and 
       FIG. 20  is a partial three-dimensional view of the MRAM of  FIG. 17  at a stage of processing subsequent to that shown in  FIG. 19 ; 
       FIG. 21  is a partial three-dimensional view of the MRAM of  FIG. 17  at a stage of processing subsequent to that shown in  FIG. 20 ; and 
       FIG. 22  is a schematic diagram of a processor system incorporating the MRAM constructed in accordance with the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   In the following detailed description, reference is made to various exemplary embodiments of the invention. These embodiments are described with sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be employed, and that structural and electrical changes may be made without departing from the spirit or scope of the present invention. 
   The term “substrate” used in the following description may include any semiconductor-based structure that has an exposed semiconductor surface. Structure must 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. The semiconductor need not be silicon-based. The semiconductor could be silicon-germanium, germanium, or gallium arsenide. When reference is made to substrate in the following description, previous process steps may have been utilized to form regions or junctions in or on the base semiconductor or foundation. 
   The term “metal” is intended to include not only elemental metal, but metal with other trace metals or in various alloyed combinations with other metals as known in the semiconductor art. The term “metal” is also intended to include conductive oxides of such metals, as well as doped semiconductors and their respective conductive oxides. 
   Referring now to the drawings, where like elements are designated by like reference numerals,  FIGS. 2-21  illustrate an exemplary embodiment of a method of forming MRAM structures.  FIG. 2  depicts a portion of a semiconductor substrate  50  on which underlying layer  52  has been already formed according to well-known methods of the prior art. The underlying layer  52  could include, for example, circuit layers forming CMOS devices and circuits. 
   Referring now to  FIG. 3 , an insulating layer  54  is formed over the substrate  50  and the underlying layer  52 . In an exemplary embodiment of the invention, the insulating layer  54  is blanket deposited by spin coating to a thickness of about 1,000 Angstroms to about 10,000 Angstroms. However, other known deposition methods, such as sputtering by chemical vapor deposition (CVD), plasma enhanced CVD (PECVD), or physical vapor deposition (PVD), may be used also in accordance with the characteristics of the IC device already formed. The insulating layer  54  may be formed of a conventional insulator, for example, BPSG, a thermal oxide of silicon, such as SiO or SiO 2 , or a nitride such as Si 3 N 4 . Alternatively, a high temperature polymer, such as a polyimide, or a low dielectric constant inorganic material may also be employed. 
   Next, as illustrated in  FIG. 4 , a photoresist layer  55  is formed over the insulating layer  54 . The photoresist layer  55  is exposed through a mask  56  ( FIG. 5 ) with high-intensity UV light. The mask  56  may include any suitable pattern of opaque and clear regions that may depend, for example, on the desired pattern to be formed in the insulating layer  54 . This way, portions  55   a  of the photoresist layer  55  are exposed through portions  56   a  of the mask  56  wherever portions of the insulating layer  54  need to be removed. 
   Although  FIG. 5  schematically illustrates mask  56  positioned over the photoresist layer  55 , those skilled in the art will appreciate that mask  56  is typically spaced from the photoresist layer  55  and light passing through mask  56  is focussed onto the photoresist layer  55 . After exposure and development of the exposed portions  55   a , portions  55   b  of the unexposed and undeveloped photoresist are left over the insulating layer  54 , as shown in  FIG. 6 . This way, openings  57  ( FIG. 6 ) are formed in the photoresist layer  55 . 
   An etch step is next performed to obtain grooves  58  in the insulating layer  54 , as illustrated in  FIGS. 7-8 . The grooves  58  are etched to a depth of about 500 Angstroms to about 2,000 Angstroms, more preferably of about 1,000 Angstroms. Subsequent to the formation of the grooves  58 , the remaining portions  55   b  of the positive photoresist layer  55  are then removed by chemicals, such as hot acetone or methylethylketone, or by flooding the substrate  50  with UV irradiation to degrade the remaining portions  55   b  to obtain the structure of  FIG. 8 . 
   Subsequent to the formation of the grooves  58  ( FIGS. 7-8 ), a thin barrier layer  59  is formed in the grooves  58  and over the insulating layer  54 , and then chemical mechanical polished to remove barrier layer material from the top portions of the insulating layer  54 , as shown in  FIG. 9 . The barrier layer  59  may comprise bonding materials such as tantalum (Ta), titanium (Ti), titanium-tungsten (TiW), titanium nitride (TiN) or chromium (Cr), among others. The barrier layer  59  forms a strong mechanical and chemical bond between the conductive material which will be formed later and the insulating layer  54  to help prevent peeling of the formed conductive layer from the insulating layer. In a preferred embodiment of the invention, the barrier layer  59  is formed of sputtered tantalum. In this embodiment, tantalum is deposited to a thickness of about 5 nm to about 10 nm. This layer may also be comprised of a ferromagnetic material deposited on the barrier or in place of the barrier for the purpose of field focusing. 
   Next, as illustrated in  FIG. 10 , a conductive material layer  60  is formed over the barrier layer  59  and the insulating layer  54  to fill in the grooves  58 . In a preferred embodiment, the conductive material comprises copper (Cu). However, other conductive materials such as aluminum, tungsten or gold, among others, may be used also. Further, metal alloys may be employed also, depending on desired characteristics of the IC device. 
   The conductive material layer  60  is formed over the barrier layer  59  by deposition, for example, and then excess material is removed to form metal lines  62  ( FIG. 11 ). In an exemplary embodiment of the present invention, the excess conductive material layer  60  is removed by means of chemical mechanical polishing (CMP). The top surfaces of the barrier layer  59  and the metal lines  62  are generally flat and uniform across the entire surface of the substrate, as shown in  FIG. 11 . Each metal line  62  will form the bit or digit line of a conventional MRAM structure. 
   However, after the CMP polishing process, the top surfaces of the metal line  62  and barrier layer  52  as well as insulating layer  54 , although generally flat, may still have unwanted, unflat topography as shown by the roughened portions  62   a  of metal line  62  and the protruding portion  59   a  of barrier layer  59 . This is caused by slight variations in CMP selectivity to insulating layer  54 , metal line  62  and barrier layer  59 . Such unwanted topography can negatively affect performance of MRAM structures  100 . 
   Hence, in an exemplary embodiment of the present invention as shown in  FIG. 12 , a second conductor layer or material layer  63  is formed over the upper surface of barrier layer  59 , metal line  62  and insulating layer  54 . Consequently, roughened portions  62   a  and protruding portions  59   a  are conformally covered by the second conductor layer  63 . The second conductor layer  63  may comprise bonding materials such as tantalum (Ta), titanium (Ti), titanium-tungsten (TiW), titanium nitride (TiN) or chromium (Cr), among others. In a preferred embodiment of the invention, the conductor layer  63  is formed of sputtered tantalum. In this embodiment, tantalum is deposited to a thickness of about 5 nm to about 50 nm. In addition, this layer may be used as a series resistor by including a resistive material such as TaN, WsiN or other materials. The resistor layer can be deposited under the metal layer to be smoothed in order to preserve its thickness or in place of the conductor layer  63 . 
   Next, as shown in  FIG. 13 , second conductor layer  63  is lightly polished to provide a planar surface for the subsequent fabrication of MRAM structures  100  (as described below). The term “lightly polished” is defined herein as polishing enough to planarize or flatten the second conductor layer  63  but not enough to pattern define. In other words, a top portion of the second conductor layer  63  overlying layer  54  are etched in subsequent steps (i.e., defining of the magnetic stack). Note, although roughened portions  62   a  and protruding portions  59   a  are not shown, they are still present in the intermediate structure of  FIG. 13 . However, as noted above, they are covered by the planarized second conductor layer  63  and have been omitted from  FIG. 13  for simplicity. Further, in the proceeding FIGS., conductor layer  63  is shown as simply the interface for the MRAM structure  100  and the metal line  62 /barrier layer  59 . 
   Next, the processing steps for the completion of the MRAM structures  100  are carried out. As such, a plurality of magnetic multilayer films constituting a first magnetic member  79  are first formed over the metal lines  62 , which will be later patterned into pinned layers  91  ( FIG. 18 ). The first magnetic member  79  is formed of various material layers, described below in more detail, which are successively deposited over the metal lines  62  and the insulating layer  54 , as illustrated in  FIG. 14 . 
   In an exemplary embodiment of the present invention and as illustrated in  FIG. 14 , a first tantalum (Ta) layer  71  (of about 20-400 Angstroms thick, more preferably of about 50 Angstroms thick), a first nickel-iron (NiFe) layer  73  (of about 10-100 Angstroms thick, more preferably of about 60 Angstroms thick), a manganese-iron (MnFe) layer  75  (of about 10-100 Angstroms thick, more preferably of about 100 Angstroms thick) and a second nickel-iron (NiFe) layer  77  (of about 10-100 Angstroms thick, more preferably of about 60 Angstroms thick) are successively blanket deposited over the insulating layer  54  and the metal lines  62 , to form the first magnetic member  79 . Deposition of the layers  71 ,  73 ,  75  and  77  may be accomplished by magnetron sputtering, for example. However, other conventional deposition methods may be used also, as desired. 
   Following the deposition of the layers  71 ,  73 ,  75  and  77 , a nonmagnetic, electrically nonconductive layer  80  formed of, for example, aluminum oxide (Al 2 O 3 ) (of about 5-25 Angstroms thick, more preferably of about 15 Angstroms thick) is next formed overlying the first magnetic member  79 , as shown in  FIG. 15 . Although aluminum oxide is the preferred material, it must be understood that the invention is not limited to its use, and other non-magnetic materials, such as titanium oxide (TiO 2 ), magnesium oxide (MgO), silicon oxide (SiO 2 ) or aluminum nitride (AIN), may be used also. 
   Referring now to  FIG. 16 , a plurality of magnetic multilayer films forming a second magnetic member  89  are next formed over the nonmagnetic layer  80 . Accordingly, in an exemplary embodiment of the present invention, a third nickel-iron (NiFe) layer  81  (of about 10-100 Angstroms thick, more preferably of about 40 Angstroms thick), a second tantalum (Ta) layer  83  (of about 10-100 Angstroms thick, more preferably of about 50 Angstroms thick) and a conductive layer  85  (of about 100-400 Angstroms thick, more preferably of about 200-300 Angstroms thick) are successively blanket deposited over the nonmagnetic layer  80 , to form the second magnetic member  89 , as shown in  FIG. 16 . Deposition of the layers  81 ,  83  and  85  may be accomplished by magnetron sputtering, for example, but other conventional deposition methods may be used also, depending on the characteristics of the IC devices constructed previously to the formation of the MRAM structures  100  ( FIG. 21 ). 
   In an exemplary embodiment of the present invention, the conductive layer  85  may be formed of tungsten nitrogen (WN), which is deposited to a thickness of about 100-400 Angstroms, more preferably of about 200-300 Angstroms. However, the invention is not limited to this exemplary embodiment, this layer may be comprised of a resistive material such as WN, TaN, WSiN, and others. This layer may act as a series resistor and or a CMP stopping layer dependent on the material and thickness chosen. Materials such as a-c amorphous carbon, various oxides and nitrides may be used as CMP stops as well as series resistors. 
   Next, layers  71 ,  73 ,  75 ,  77 ,  80 ,  81 ,  83  and  85  ( FIGS. 14-16 ) are patterned into a plurality of MRAM structures or cells  100  ( FIGS. 17-18 ) including columns of pinned layers  91  and rows of sense layers  92 . Thus, each MRAM structure  100  includes the pinned layer  91  (as part of the first magnetic member  79 ) separated from a sense layer  92  (as part of the second magnetic member  89 ) by the nonmagnetic layer  80 . For simplicity, the multilayer stack forming the pinned layer  91  is illustrated in  FIG. 16  as a single layer. Similarly, the multilayer stack forming the sense layer  92  is also illustrated in  FIG. 18  as a single layer. It must be understood, however, that the pinned layer  91  includes portions of the copper line  62  and of the layers  71 ,  73 ,  75  and  77 , while the sense layer  92  includes portions of the layers  81 ,  83  and  85 . 
   Patterning of the plurality of layers forming the pinned and sense layers of the MRAM structures  100  ( FIG. 18 ), that is patterning of layers  71 ,  73 ,  75 ,  77 ,  80 ,  81 ,  83  and  85  may be accomplished by ion milling which typically involves physical sputtering of each layer by an argon ion beam. Patterning may be also accomplished by using a reactive plasma etch, performed, for example, in electron cyclotron resonance (ECR) or other high density plasmas, such as an inductively coupled plasma system, or a helicon plasma system containing chlorine as the source gas. A mixture of chlorine with other gases, such as argon, neon or helium, among others, may be used also. In any event, the pinned and sense layers  91 ,  92  are patterned and etched so that the pinned layers  91  correspond to the metal lines  62  that form the bottom electrodes of the pinned layers  91 . 
   Next, an insulating layer  95  ( FIG. 19 ) is formed overlying the substrate  50  including the MRAM structures  100  to a thickness of about 90-10,000 Angstroms, more preferably of about 5,000 Angstroms. The insulating layer  95  completely fills the spaces between any adjacent MRAM structures  100 , as shown in  FIG. 19 . In an exemplary embodiment of the invention, the insulating layer  95  is formed of a nitride material such as silicon nitride (Si 3 N 4 ), which may be formed by conventional deposition methods, such as sputtering by chemical vapor deposition (CVD), plasma enhanced CVD (PECVD), or physical vapor deposition (PVD), among others. However, other conventional insulating materials, for example, BPSG, aluminum oxide, a thermal oxide of silicon, such as SiO or SiO 2 , or a high temperature polymer, such as a polyimide, a low dielectric constant inorganic material, amorphous dielectric, or bias sputtered quartz may also be employed. 
   Subsequent to the formation of the insulating layer  95  ( FIG. 19 ), portions of the insulating layer  95  that are formed over the top surface of the MRAM structures  100  are removed by means of chemical mechanical polishing (CMP) or well-known RIE dry etching processes. In an exemplary embodiment of the invention, the insulating layer  95  is chemical mechanical polished so that an abravise polish removes the top surface of the insulating layer  95  above the MRAM structures  100 , down to or near the planar surface of the top surface of the conductive layer  85 , to form respective MRAM contacts  99  in a polished insulating layer  96 , as illustrated in  FIG. 20 . This way, the conductive layer  85 , which was formed as part of the sense layer  92  of the MRAM structure  100 , acts as a polishing stop layer in the formation of the contacts  99 . 
   Additional steps to create a functional MRAM cell having a contact may be carried out. For example,  FIG. 21  illustrates schematically three MRAM cell structures  100  coupled to a word line  93  that intersects three pinned layers  91  and associated sense layers  92  at respective MRAM contacts  99 . As known in the art, the word line  93  may be formed of copper, for example, by patterning a mask on a dielectric layer, which is formed over the sense layers  92  including the MRAM contacts  99 , and by forming a trench in which conductive word line  93  is formed on a direction orthogonal to that of the sense layer  92 . For a better understanding of the invention, the polished insulating layer  96  has been omitted in  FIG. 21  to illustrate the pinned layers and sense layers  91 ,  92  below the word line  93 . However, it must be understood that the space between the pinned layers and sense layers  91 ,  92  and below the word line  93  is filled with the insulating layer  96 . 
   Although  FIG. 21  illustrates MRAM contacts  99  in direct contact and adjacent to the word line  93 , it must be understood that the invention is not limited to this embodiment, and other interceding structures, such as conductive plugs and/or metal lines from the MRAM contacts  99  to the word line  93  may be formed also, as desired. 
   A typical processor based system  400  which includes a memory circuit  448 , for example an MRAM with MRAM cell structures  100  having MRAM contacts  99  ( FIGS. 20-21 ) constructed according to the present invention is illustrated in  FIG. 22 . A processor system, such as a computer system, generally comprises a central processing unit (CPU)  444 , such as a microprocessor, a digital signal processor, or other programmable digital logic devices, which communicates with an input/output (I/O) device  446  over a bus  452 . The memory  448  communicates with the system over bus  452 . 
   In the case of a computer system, the processor system may include peripheral devices such as a floppy disk drive  454  and a compact disk (CD) ROM drive  456  which also communicate with CPU  444  over the bus  452 . Memory  448  may be combined with the processor, i.e. CPU  444 , in a single integrated circuit. 
   Although the exemplary embodiments described above illustrate the formation of three MRAM cell structures  100  having respective MRAM contacts  99  ( FIGS. 20-21 ) it is to be understood that the present invention contemplates the use of a plurality of MRAM contacts  99  of pinned layers and sense layers as part of a plurality of MRAM cells arranged, for example, in rows and columns in a memory cell array. In addition, although the exemplary embodiments described above refer to a specific topography of the MRAM structures with specific magnetic materials forming such structures, it must be understood that the invention is not limited to the above-mentioned magnetic materials, and other magnetic and ferromagnetic materials, such as nickel-iron (Permalloy) or iron, among others, may be used also. Further, although the exemplary embodiments described above refer to patterning of the MRAM structures by reactive plasma etching, it must be understood that the present invention contemplates the use of other methods of patterning and etching. 
   The present invention is thus not limited to the details of the illustrated embodiment. Accordingly, the above description and drawings are only to be considered illustrative of exemplary embodiments which achieve the features and advantages of the present invention. Modifications and substitutions to specific process conditions and structures can be made without departing from the spirit and scope of the present 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.

Technology Category: 5