Patent Document

CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This is a divisional application of pending U.S. patent application Ser. No. 11/001,936 filed Dec. 2, 2004. 
     
    
     TECHNICAL FIELD  
       [0002]     The invention relates to non-volatile memory transistor construction, and, more specifically, to a manufacturing method for a transistor employing nanocrystals.  
       BACKGROUND ART  
       [0003]     Non-volatile memory designs continue to improve with technological advancements. Floating gate and MONOS (metal/polysilicon oxide nitride oxide silicon) are types of non-volatile memories. In conventional floating gate structures, charge is stored on to a floating gate, by either Fowler-Nordheim tunneling or by source side injection. The cell operation is governed by electron charge storage on an electrically isolated floating gate. The amount of charge stored modulates the memory cell&#39;s transistor characteristic. Because the only electrical connection to the floating gate is through capacitors, the memory cell can be thought of as a linear capacitor network with an attached N-channel transistor. Any charge present on the floating gate is retained due to the inherent Si-SiO 2  energy barrier height, leading to the non-volatile nature of the memory cell.  
         [0004]     MONOS memory cells, in comparison to standard floating gate cells, may have faster program times and higher densities. In MONOS memory cells using sidewall spacer structures, a source side electron injection approach is faster and may require lower voltages than electron tunneling methods used for a standard floating gate design. U.S. Pat. No. 6,686,632, to Ogura et al. describes a dual bit MONOS memory having a twin cell structure. The cell structure is realized by placing sidewall control gates over a composite of oxide nitride oxide (ONO). Both sides of a word gate and control gates are formed using a disposable sidewall process. During construction of this device, a sidewall spacer is required for the word gate to accommodate the ONO and source side injection structure.  
         [0005]     Newer processes that may be used in non-volatile memory designs also continue to be developed. For example, metal nanocrystal memories have been utilized to enhance the performance of memory cell devices to improve the work function. In a nanocrystal non-volatile storage device, charge is not stored on a continuous floating gate layer. Instead, a large number of discrete mutually isolated nanocrystals are contained on a semiconductor layer. Nanocrystals may be employed in storing small amounts of electrical charge, even being able to store a single, or a small number, of atoms. In theory, smaller transistors may be made because structures containing nanocrystal charge storage “dots” might be made exceedingly small.  
         [0006]     A downside to using nanocrystals has been high power consumption due to refresh requirements, short retention time, and high capacitance. U.S. Pat. No. 6,165,842, to Shin et al. describes a method for fabricating a nonvolatile memory device using crystal dots. A tunneling dielectric, a thin amorphous silicon film, a polysilicon layer having nanocrystals, a dielectric layer, and a polysilicon film are formed. The method develops a nonvolatile memory cell gate structure having dimensions limited by the resolution of optics or photoresist materials used in photolithography and must develop a multitude of layers to support and construct a nanocrystal layer.  
         [0007]     Such devices are therefore difficult to manufacture because nanocrystals are many times smaller than photolithography resolution limits currently used in manufacturing integrated circuits.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention is a manufacturing method for an improved memory cell device employing nanocrystals to reduce an overall size of each memory cell gate, and therefore reduce the overall integrated circuit or die size of a memory circuit. In accordance with the present invention, a nanocrystal layer is used in the construction of a dual bit non-volatile memory structure. A plurality of trenches are developed to reduce the gate area or each memory cell which uses a nanocrystal charge storage region. Charge is transferred through a thin tunneling barrier to the nanocrystals. The method forms a memory cell gate using a plurality of offset trenches to expose and remove a portion of a nanocrystal layer to develop a nanocrystal gate area having at least one dimension that is smaller than current photolithography resolution limits. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1A  is a cross section of an exemplary beginning structure of a substrate with a nanocrystal stack, and a first polysilicon layer formed above it. Also shown are a formed oxide layer, nitride layer, oxide layer and a patterned photoresist mask.  
         [0010]      FIG. 1B  is an enlarged cross section al area of the nanocrystal stack of  FIG. 1A , comprised of a tunnel oxide layer, a nanocrystal layer, and a control oxide layer.  
         [0011]      FIG. 2  is a cross section of  FIG. 1A  after a portion of the oxide nitride oxide have been removed and the patterned photoresist mask has been removed.  
         [0012]      FIG. 3  is a cross section of  FIG. 2  after a fifth oxide has been formed on the sidewalls of oxide mesa structures.  
         [0013]      FIG. 4  is a cross section of  FIG. 3  after an exposed portion of the first polysilicon layer has been selectively removed.  
         [0014]      FIG. 5  is a cross section of  FIG. 4  after a first dopant has been formed in the underlying substrate.  
         [0015]      FIG. 6  is a cross section of  FIG. 5  after a portion of the nanocrystal stack has been selectively removed and a second dopant has been selectively formed in the exposed substrate.  
         [0016]      FIG. 7  is a cross section of  FIG. 6  after a sixth oxide has been formed over the dopant area and mesa structures.  
         [0017]      FIG. 8  is a cross section of  FIG. 7  after a portion of the sixth oxide has been selectively removed and a third dopant has been selectively formed in the exposed substrate.  
         [0018]      FIG. 9  is a cross section of  FIG. 8  after a second polysilicon layer has been formed.  
         [0019]      FIG. 10  is a cross section of  FIG. 9  after a portion of the second polysilicon layer has been selectively removed.  
         [0020]      FIG. 11  is a cross section of  FIG. 10  after a fifth oxide layer has been formed.  
         [0021]      FIG. 12  is a cross section of  FIG. 11  after a portion of the seventh oxide layer has been selectively removed.  
         [0022]      FIG. 13  is a cross section of  FIG. 12  after the nitride structure has been removed.  
         [0023]      FIG. 14  is a cross section of  FIG. 13  after a portion of the remaining oxide layers and a portion of the second polysilicon layer have been selectively removed.  
         [0024]      FIG. 15  is a cross section of  FIG. 14  after an eighth oxide layer has been deposited.  
         [0025]      FIG. 16  is a cross section of  FIG. 15  after a portion of the eighth oxide layer and the nanocrystal stack has been removed.  
         [0026]      FIG. 17  is a cross section of  FIG. 16  after a word line gate oxide has been formed above the exposed substrate.  
         [0027]      FIG. 18  is a cross section of  FIG. 17  after a third polysilicon layer has been deposited.  
         [0028]      FIG. 19  is a cross section of  FIG. 18  after a portion of the third polysilicon layer and top oxide have been removed.  
         [0029]      FIG. 20  is a cross section of the memory cell structures indicating various memory cell structure elements.  
         [0030]      FIG. 21  is a circuit diagram of a dual memory cell as shown in  FIG. 20 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0031]     Collectively, individual nanocrystals in a nanocrystal memory gate can control the channel conductivity of a memory cell. Each nanocrystal individually stores a small number of electrons. One of the advantages of a nanocrystal charge storage gate is an ability to use thinner tunnel oxides and shorter channel lengths and therefore, a smaller cell area may be developed. In addition, the stored charge (electrons) in a nanocrystal charge storage gate may be directed to a specific area within the storage gate area and can be configured to store a single logic state (bit) or multiple logic states (bits) within a given cell.  
         [0032]     With reference to an exemplary process beginning with  FIG. 1A , a substrate  10  having a p-well or p-type substrate material is used. The p-well is developed by doping a surface of the substrate with, for example, boron. A nanocrystal stack  20  is formed above the substrate  10 . The nanocrystal stack  20 ,  FIG. 1B , is composed of a thin tunnel oxide layer  21  (a first oxide), a thin nanocrystal layer  22 , and a thin control oxide layer  23  (a second oxide). In a specific embodiment, the nanocrystal stack  20  will have an average thickness of approximately 120-180 Angstroms. The tunnel oxide layer  21  may generally have a thickness of 20-50 Angstroms; the nanocrystal layer  22  may generally have a thickness of 20-60 Angstroms; and the control oxide layer  23  may generally have a thickness of 60-100 Angstroms.  
         [0033]     The nanocrystals may be comprised of any material such as a silicon, germanium, Si-Ge, or metal, and the nanocrystal layer will typically have an approximate 50% to 75% area coverage of nanocrystals. In a specific embodiment, the nanocrystal area coverage will be approximately 60%. The nanocrystal layer  22  may be fabricated by various techniques including chemical vapor deposition, low energy implantation, or by aerosol formation.  
         [0034]     With reference again to  FIG. 1A , in the formation of a memory cell structure, a first polysilicon layer  30  is formed over the nanocrystal stack  20  (tunnel oxide  21 , nanocrystal  22 , and control oxide  23  layers).  
         [0035]     Above the first polysilicon layer  30  a third oxide layer  40 , a nitride layer  41 , and a fourth oxide layer  42  are formed. Referring to  FIG. 2 , a portion of the fourth oxide layer  42 , nitride layer  41 , and third oxide layer  40  are then selectively removed for example, using a patterned photoresist mask  50  and an etch process. After the patterned photoresist mask  50  is removed, a sacrificial mesa (or island) structure  51  remains, composed of portions of the third oxide layer  40 , nitride layer  41 , and the fourth oxide  42 .  
         [0036]     In reference to  FIG. 3 , a fifth oxide layer  43  is formed over the exposed edges or sidewalls of the sacrificial mesa structure  51 , for example using a chemical vapor deposition of oxide followed by, for example patterning and an anisotropic etch process, leaving a fifth oxide layer  43  on both sides of the sacrificial mesa structure  51  and over the top portion of the mesa structure, depending upon the deposition process used. The fifth oxide layer  43  will be used as a hard mask during a subsequent removal or etch process. Next, a portion of the underlying first polysilicon layer  30  is removed, for example by a selective etch process. The removal or etch process selectively removes a portion of the first polysilicon layer  30  and forms a first trench  52  in the first polysilicon layer  30  as shown in  FIG. 4 .  
         [0037]     Next, several steps will be used to develop channel, source, and drain areas for a dual cell memory structure. With reference to  FIG. 5 , a first n-type doped area  54  is formed in the substrate  10 , for example by high angle tilt ion implantation, approximately near the bottom of the first trench  52  or approximately in an area where the nanocrystal stack  20  is exposed. The mesa structure  51  and the first trench  52  will be used as a self-aligning mask and may affect the shape and depth of the first doped area  54  under the nanocrystal stack  20 . The first doped area  54  extends partially under the remaining first polysilicon layer  30  and nanocrystal stack  20 .  
         [0038]     Next, referring to  FIG. 6 , the exposed portion of the nanocrystal stack  20  in the first trench  52  is removed. In an alternative embodiment an underlying portion of the substrate  10  may be over-etched to form a depression in the first doped area  54 . A second doped area  55  is formed in the area proximate to the first doped area  54 . Referring to  FIG. 7 , a sixth oxide layer  44  is formed over the previously described structures and subsequently etched to expose the second doped area  55  approximately at the bottom of the first trench  52 . A third doped area  56  is then formed in the substrate  10  near the bottom of the first trench  52  as shown in  FIG. 8 .  
         [0039]     Referring to  FIG. 9 , a second polysilicon layer  31  is then formed over the doped areas  54 ,  55 ,  56  of the substrate  10  and mesa structures  51 , filling the first trench  52 . Next, an upper portion of the second polysilicon layer  31  is then selectively removed, leaving a portion of the first trench  52  filled with a portion of the second polysilicon layer  31  as shown in  FIG. 10 . Next, referring to  FIG. 11 , a seventh oxide layer  45  is formed, such as a TEOS oxide layer, covering the above described structures and features. A portion of the seventh oxide layer  45  is subsequently removed. A CMP (chemical mechanical planarization) step may be performed to remove a portion of the seventh oxide  45 . An exemplary CMP step may also be performed to remove a portion of the seventh oxide layer  45 . A portion of the nitride layer  41  under the seventh oxide layer has been exposed as shown in  FIG. 12 .  
         [0040]     Next, with reference to  FIG. 13 , the remaining portion of the nitride layer  41  feature is removed, for example by using a high selectivity wet etch technique. Removal of the remaining nitride layer  41  provides breaks  46  in the remaining oxide layer  47 . Referring to FIG.  14 , a portion of the remaining oxide layer  47  is removed, and a portion of the first polysilicon layer  30  is also removed, forming second trenches  57  in the first polysilicon layer  30 . In one embodiment, the second trench is offset from the first trench location by a distance that is smaller than a photolithography resolution limit in an optical process. The underlying control oxide  23  (see  FIG. 1B ) in the nanocrystal stack  20  may be used as an etch stop for the polysilicon etch.  
         [0041]     Referring to  FIG. 15 , an eighth oxide  48  is formed over the sidewalls of the remaining first polysilicon layer, and the control oxide layer  23  of the nanocrystal stack  20 . In one embodiment, the eighth oxide  48  may be formed by a chemical vapor deposition process. Next, with reference to  FIG. 16 , the eighth oxide  48  at the bottom of the second trench is selectively removed. The removal process also removes a portion of the thin control oxide layer  23  in the nanocrystal stack  20 , for example using an etch process, to expose the nanocrystal layer  22 . The exposed portion of the nanocrystal layer  22  is removed to expose the underlying tunnel oxide  21  and, the exposed tunnel oxide  21  is also removed.  
         [0042]     With reference to  FIG. 17 , a gate structure  24  for a nonvolatile memory cell has now been formed. Using a nanocrystal gate structure provides an advantage or using thinner tunnel oxides without sacrificing breakdown and leakage parameters, allowing lower operating voltages and/or increasing operating speed. When hot carriers are injected into the nanocrystal layer  22  ( FIG. 1B ), there is less carrier scattering, in the depleted layer underneath the gate and less energy is required to move carriers into the nanocrystals in the nanocrystal layer  22 . Using nanocrystals within the gate structure  24  also allows the use of shorter channel lengths and therefore smaller cell sizes. In the formation process, removing portions of the nanocrystal stack  20  using a two-trench approach allows a nanocrystal gate structure to be built having dimensions that are smaller compared to developing a gate directly from a photoresist mask using, a standard photolithography process. Applying a two-trench formation method provides a process to build smaller structures and to reap the technological advantages and improvements that nanocrystal containing structures have to offer.  
         [0043]     Next, a cleaning operation may be performed to prepare the wafer surface for a subsequent oxidation step. With continued reference to  FIG. 17 , a gate oxidation step forms a word line gate structure  25 . In  FIG. 18 , after a word line gate structure  25  has been formed, a third polysilicon layer  32  is formed, filling the second trenches  57 . The third polysilicon layer  32  will provide a conductive path for a conventional word line control device. Referring to  FIG. 19 , a portion of the third polysilicon layer  32  and an upper portion of the remaining oxide layer  48  is then removed, exposing remaining portions of the first polysilicon layer  30  and the second polysilicon layer  31 . For example, a chemical mechanical planarization step may be performed, and a cleaning process may be used to prepare the wafer surface for forming additional polysilicon or metal interconnections. The exposed portions of the first  30 , second  31 , and third  32  polysilicon layers provide conductive paths to the underlying structures. The exposed polysilicon  30 ,  31 ,  32  will be further developed or coupled to interconnections including a word line, bit line, and/or control gate line. A variety of subsequent processes may be performed to form the conductive interconnections to produce an integrated circuit memory chip.  
         [0044]     A basic non-volatile dual memory cell structure of  FIG. 20  (without interconnections), is schematically represented in  FIG. 21 . Two memory cells  70 ,  71  are serially coupled by a word line device  72  having gate portions  62  and  67 . Each memory cell  70 ,  71  is also coupled to a conductive control gate line  60 ,  61  and a bit line  64 ,  68 . The drain and source of each memory cell  70 ,  71 , having a nanocrystal area  65 ,  66  to store electrons, provide the functions for a dual non-volatile memory cell structure.  
         [0045]     Presented in this description is an exemplary structure and fabrication method for a dual multi-bit memory cell. It is to be understood that the above description is intended to be illustrative, and not restrictive. Those of skill in the art will recognize that the invention can be practiced with modification and alteration within the spirit and scope of the appended claims and many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. The procedures for formation, for example, the formation of shallow trench isolation areas, p-well, and n-well are similar to conventional CMOS processing and, although not shown or described, these processes or structures may be used with the invention described. Other processes such as the formation of oxides, polysilicon layers, or nitride layers may be performed by other processes not described but known to one of skill in the art. Masking processes with exposures, development, and vertical or horizontal etching of layers may be performed by a variety of processes including chemical etching or ion milling. The description is thus to be regarded as illustrative rather than limiting. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which said claims are entitled.

Technology Category: h