Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of U.S. application Ser. No. 12/489,440 filed Jun. 23, 2009, which is included herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to semiconductor memory devices and methods for making such devices. More particularly, this invention relates to a phase-change memory (PCM) device utilizing a diode-selected array and a self-aligned method for fabricating the same. 
     2. Description of the Prior Art 
     Phase-change memory (PCM) is a type of non-volatile computer memory, which uses the unique behavior of phase-change materials such as chalcogenide glass. With the application of heat, the chalcogenide glass can be switched between two states, i.e., crystalline and amorphous states. The crystalline and amorphous states of chalcogenide glass have dramatically different electrical resistivity, and this forms the basis by which data are stored. 
       FIG. 1  is a schematic diagram showing a cross-sectional view of a conventional phase-change memory cell structure. As shown in  FIG. 1 , the phase-change memory cell structure includes a silicon substrate  10  with a bottom electrode  12  thereon. A dielectric layer  14  is formed over the bottom electrode  12  and a heating electrode  16  is formed in the dielectric layer  14 . A patterned phase-change material layer  20  is provided on the dielectric layer  14 . The patterned phase-change material layer  20  may be formed in a dielectric layer  18 . A bottom surface of the phase-change material layer  20  partially contacts the heating electrode  16 . A dielectric layer  24  is formed over the dielectric layer  18  and a top electrode  22  is formed over and in the dielectric layer  24 , thereby contacting the phase-change material layer  20 . During memory cell operation, a large amount of current flows through the heating electrode  16  to heat up an interface between the phase-change material layer  20  and the heating electrode  16 , thereby transforming the phase of the phase-change material layer  20 . 
     Currently, to enhance applications of phase-change memory devices, size of the memory cells of the phase change memory devices is being required to be further reduced. With size reduction of the memory cell, however, it also means working current of the memory cells should also be reduced while increasing memory cell density. One challenge for current phase-change memory technology has been the requirement of high programming current density in the active volume for switching the state of the phase-change material during a write operation. One approach is reducing the contact surface area between the heating electrode  16  and the phase change material layer  20 , such as through reducing a diameter D o  of the heating electrode  16 , thereby maintaining adequate current density at the interface. However, diameter scalability of the heating electrode  16  is limited by ability of current photolithography. 
     The contact between the hot phase-change region and the adjacent dielectric is another fundamental concern. The dielectric may begin to leak current at higher temperature, or may lose adhesion when expanding at a different rate from the phase-change material. 
     SUMMARY OF THE INVENTION 
     It is one object of the invention to provide a high-density phase-change memory device with improved phase-change efficiency and reduced switching time. 
     It is another object of the invention to provide a cost-effective method for manufacturing such phase-change memory device in a self-aligned fashion to thereby solve the aforementioned challenges and improve electrical performance of conventional phase-change memory devices. According to the preferred embodiment of the invention, at least one conventional photo mask for patterning the phase-change material can be spared, thus making the present invention method more economical than the prior art. 
     According to the claimed invention, in accordance with one preferred embodiment, a phase-change memory cell structure includes a bottom diode on a substrate; a heating stem on the bottom diode; a first dielectric layer surrounding the heating stem, wherein the first dielectric layer forms a recess around the heating stem; a phase-change storage cap capping the heating stem and the first dielectric layer; and a second dielectric layer covering the first dielectric layer and the phase-change storage cap wherein the second dielectric layer defines an air gap in the recess. 
     In one aspect, in accordance with another embodiment of the invention, a method for fabricating a phase-change memory cell includes providing a substrate having thereon a plurality of buried address lines and a first dielectric layer on the substrate; forming a conductive electrode in the first conductive layer; removing a portion of the first dielectric layer thereby exposing a top portion of the conductive electrode; depositing a second dielectric layer on surface of the top portion and on the first dielectric layer, wherein the second dielectric layer defines a recess around the top portion and on the first dielectric layer; depositing a third dielectric layer over the second dielectric layer, wherein the third dielectric layer fills into the recess; performing a planarization process to remove a portion of the third dielectric layer and a portion of the second dielectric layer, thereby exposing a top surface of the top portion of the conductive electrode; salicidizing the top portion of the conductive electrode to form a heating stem; selectively removing the remaining third dielectric layer from the recess; forming a phase-change material layer covering the heating stem and the second dielectric layer; and performing a self-aligned etching process to etch the phase-change material layer, thereby forming a phase-change storage cap. 
     These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram showing a cross-sectional view of a conventional phase-change memory cell structure. 
         FIGS. 2-16  are schematic, cross-sectional diagrams demonstrating a method of fabricating a phase-change memory cell in accordance with one preferred embodiment of this invention. 
         FIG. 17  is an alternative embodiment of the process as depicted in  FIG. 13  according to this invention. 
         FIG. 18  is another variant of  FIG. 13  in accordance with yet another embodiment of this invention. 
         FIG. 19  is a plan view schematically showing the layout of PCM storage cap and the upward protruding cylindrical features of  FIG. 14  after performing the self-aligned etching process. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims. Embodiments of phase-change memory devices and methods for manufacturing the same are described as below incorporating  FIGS. 2-18 . 
     As shown in  FIG. 2 , a substrate  100  such as a semiconductor substrate or a P type silicon substrate is provided. Active devices such as transistors, diodes or thin films such as dielectric layers may be formed on the substrate  100  but are not illustrated here. The substrate  100  is merely illustrated as a planar substrate without showing the layers or active devices formed thereon for the sake of simplicity. A plurality of N+ buried address lines or N+ buried base lines  102  are formed in the substrate  100 . The formation of the N+ buried base lines  102  may be accomplished by conventional lithographic processes and ion implantation process. For example, a mask such as a patterned photoresist layer (not shown) defining the N+ buried base lines  102  is first formed on the substrate  100 . An ion implantation process is then carried out to implant N type dopants such as arsenic or phosphorus into the substrate  100  through the openings in the patterned photoresist layer. After removing the patterned photoresist layer, an anneal process may be carried out to activate the dopants. After the formation of the N +  buried base lines  102 , a dielectric layer  103  is then deposited over the substrate  100 . The dielectric layer  103  may comprise borophosphosilicate glass (BPSG), silicon oxide, spin-on glass (SOG) or silicon nitride formed by, for example, chemical vapor deposition or spin-on methods. 
     As shown in  FIG. 3 , subsequently, a photolithographic process (bit line photo patterning) and an etching process are carried out to form openings  103   a  in the dielectric layer  103 . The openings  103   a  is formed through the dielectric layer  103  and each of the openings  103   a  partially exposes a portion of the underlying N+ buried base lines  102 . 
     As shown in  FIG. 4 , a layer of conductive material is then blanketly deposited over the dielectric layer  103  and fills the openings  103   a . The portion of the conductive material outside the openings  103   a  and above the dielectric layer  103  is then removed by a planarization process such as a chemical mechanical polishing (CMP) process, thereby leaving a conductive electrode  104  in each of the openings  103   a  and exposing a top surface of the conductive electrode  104 . According to this embodiment, the conductive electrode  104  may comprise doped polysilicon, doped Si, doped SiGe, TiW, or TiN. 
     As shown in  FIG. 5 , an etching process is then performed to remove portions of the dielectric layer  103  and exposes a top portion  104   a  of each of the conductive electrodes  104 . According to this embodiment, the top portion  104   a  of each of the conductive electrodes  104  is exposed with a height H of about 10-5000 angstroms, preferably of about 100-4000 angstroms. In addition, the conductive electrode  104  is formed with a diameter D 1  that is determined by the process capability of the photolithography process for forming the openings  103   a . The conductive electrodes  104  may function as a heating electrode for heating up a sequentially formed phase change material layer. 
     As shown in  FIG. 6  and  FIG. 7 , an oxidation process is then performed to partially oxidize the exposed top portion  104   a  of each of the conductive electrodes  104 , thereby forming an oxide layer  104   b  over the surface of the exposed top portion  104   a  of each of the conductive electrodes  104 . The oxidation process may be a furnace oxidation process which is performed under a temperature of about 500-1000° C. for a time period of about 1-600 minutes. Process time and temperature of the oxidation process is not limited to those disclosed above and may vary according to materials used in the conductive electrode  104 . The oxide layer  104   b  is formed on a top surface and sidewall surfaces of the exposed top portion  104   a  of each of the conductive electrode  104 . The oxide layer  104   b  may slightly penetrate downward to a portion of the conductive electrode  104  below the top surface of the dielectric layer  103 . The oxide layer  104   b  is then removed or stripped by methods known in the art such as wet etching, as shown in  FIG. 7 . At this point, the top portion  104   a  is shrunk with a reduced dimension D 2 . Alternatively, to shrink the top portion  104   a  of each of the conductive electrodes  104 , a wet etching process may be used instead of the oxidation process. 
     As shown in  FIG. 8 , a dielectric layer  105  is conformally deposited over the dielectric layer  103  and over the shrunk top portion  104   a  of the conductive electrode  104 . The dielectric layer  105  forms a recess  105   a  between neighboring top portions  104   a  of the conductive electrodes  104 . The recess  105   a  is formed around each of the top portion  104   a  of the conductive electrode  104 . According to the embodiment, the dielectric layer  105  may comprise silicon nitride or silicon oxide and may have a thickness ranging between 50 angstroms and 500 angstroms. The dielectric layer  105  may be deposited by chemical vapor deposition methods such as PECVD. 
     As shown in  FIG. 9 , a dielectric layer  106  is deposited over the dielectric layer  105  and the dielectric layer  106  fills the recess  105   a . According to this embodiment, the dielectric layer  106  and the dielectric layer  105  are made of different dielectric materials. For example, the dielectric layer  105  is composed of silicon nitride and the dielectric layer  106  is composed of silicon oxide, whereby the dielectric layer  106  can be removed selectively from the top surface of the dielectric layer  105 . In another embodiment, the dielectric layer  105  is composed of silicon oxide, while the dielectric layer  106  is composed of silicon nitride. Likewise, the dielectric layer  106  may be deposited by chemical vapor deposition methods such as PECVD. 
     As shown in  FIG. 10 , a planarization process such as a chemical mechanical polishing (CMP) process is carried out to remove a portion of the dielectric layer  106  and a portion of the dielectric layer  105 , thereby exposing a top surface of the top portion  104   a  of each of the conductive electrodes  104  and resulting in a substantially planar surface at this stage. After the CMP, the remanent dielectric layer  106   a  is embedded in the recess  105   a  between neighboring top portions  104   a  of the conductive electrodes  104 . 
     As shown in  FIG. 11  and  FIG. 12 , a salicide process is implemented. First, a metal layer  107  is deposited over the substrate  100  by methods known in the art such as plating, sputtering, or deposition methods. According to this embodiment, the metal layer  107  may comprise cobalt, nickel, titanium or the like. The metal layer  107  directly contacts the exposed top surface of the top portion  104   a  of each of the conductive electrodes  104 . Subsequently, as shown in  FIG. 12 , the metal layer  107  reacts with the top portion  104   a  through a rapid thermal anneal (RTP) process to transform the top portion  104   a  into salicide heating stem  108  that acts as a heater of the PCM cell. The un-reacted metal layer  107  is then removed to expose a top surface of the salicide heating stem  108 . The salicide heating stem  108  is connected to a bottom diode  200  consisting of the conductive electrodes  104  embedded in the dielectric layer  103  and a portion of the N+ buried base lines  102 . 
     As shown in  FIG. 13 , after salicidizing, the remanent dielectric layer  106   a  inlaid in the recess  105   a  between neighboring top portions  104   a  of the conductive electrodes  104  is selectively removed from the surface of the dielectric layer  105 , thereby revealing the recess  105   a . The conformal dielectric layer  105  extends to the sidewalls of the salicide heating stem  108  and encompasses the salicide heating stem  108  to thereby form upward protruding cylindrical features  110 . Subsequently, a non-conformal deposition process is carried out to deposit a phase-change material layer  109  over the substrate  100 . According to this embodiment, the phase-change material layer  109  is not a conformal material layer, featuring a greater thickness atop the upward protruding cylindrical features  110  and a much thinner thickness at the sidewalls of the upward protruding cylindrical features  110  and at the bottom of the recess  105   a , thereby forming a tapered sectional profile. The non-conformal phase-change material layer  109  also features an overhang  109   a  at the inlet of each of the recess  105   a . Such non-conformal phase-change material layer  109  may be formed by non-conformal physical vapor deposition methods. The phase-change material layer  109  may comprise chalcogenide materials such as Ge—Sb—Te trinary chalcogenide compounds or Te—Sb binary chalcogenide compounds. 
     In accordance with another embodiment of this invention, the overhang  109   a  may seal the recess  105   a , thereby forming void  109   b  thereto, as shown in  FIG. 17 . In accordance with still another embodiment of this invention, the overhang  109   a  may seal the recess  105   a  and substantially no phase-change material is deposited at the bottom of the recess  105   a , as shown in  FIG. 18 . 
     As shown in  FIG. 14 , a self-aligned etching process such as a self-aligned dry etching process or a self-aligned wet etching process is carried out to etch the phase-change material layer  109 , thereby forming a phase-change storage cap or PCM storage cap  109   c  and revealing the recess  105   a  in a self-aligned fashion. According to this embodiment, the phase-change material at the bottom of the recess  105   a  is completely removed. However, it is understood that in another case the phase-change material at the bottom of the recess  105   a  may not be completely removed. The PCM storage cap  109   c  may cover an upper portion of the sidewall of the upward protruding cylindrical features  110 . In another embodiment, the PCM storage cap  109   c  may cover entire sidewall of the upward protruding cylindrical features  110  and encapsulates the upward protruding cylindrical features  110 . A plan view showing the layout of PCM storage cap  109   c  and the upward protruding cylindrical features  110  after performing the self-aligned etching process is shown in  FIG. 19 . 
     As shown in  FIG. 15 , after the self-aligned etching process, a dielectric layer  111  such as silicon oxide, silicon oxy-nitride, silicon nitride or low-k dielectrics is deposited over the substrate  100  to seal the recess  105   a , thereby forming air gap  120  inside the recess  105   a . The air gap  120  may be vacuum or near vacuum depending upon the vacuum condition during the deposition of the dielectric layer  111 . The air gap  120  surrounds the upward protruding cylindrical features  110  and may act as a heat insulator that can effectively prevent heat generated from a salicide heating stem  108  from interfering neighboring cells during the heating or setting of the phase-change material of a particular cell bit. Furthermore, the phase-change material may cover the sidewall of the upward protruding cylindrical features  110  and provide better heat insulating characteristic owing to the low thermal conductivity of the phase-change material. 
     As shown in  FIG. 16 , a plurality of bit lines  140  are formed on the dielectric layer  111  and each of the plurality of bit lines  140  is electrically connected with corresponding PCM storage cap  109   c  of a PCM cell through corresponding via/contact plug  144  that is formed in the dielectric layer  111 . According to this embodiment, the bit lines  140  may be composed of metals such as aluminum, copper, tungsten, silver, gold or alloys thereof. The via/contact plug  144  may be composed of aluminum, copper or tungsten. 
     In sum, the advantages of using this invention include: (1) at least one photo mask can be spared because the PCM storage cap is defined by self-aligned method, thus making the present invention method more economical; (2) the space between cells can be shrunk to minimum because the PCM storage cap is formed self-aligned to the salicide heating stem  108  and the bottom diode  200 , thereby increasing the cell packing density; and (3) the heater, i.e., the salicide heating stem  108 , is surrounded by air gap and, optionally, the phase-change material with low thermal conductivity, thereby avoiding cross talk between cells during operation and improving the phase-change efficiency. 
     Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.

Technology Category: h