Background of the Invention
(1) Field of the Invention
The present invention relates to a method used to create a stacked capacitor structure, for a dynamic random access memory, (DRAM) device.
(2) Description of the Prior Art
Improved device performance and the reduced manufacturing costs of these devices, are major objectives of the semiconductor industry. These objectives have been successfully addressed by the ability of the semiconductor industry to fabricate semiconductor memory chips with sub-micron features, or micro-miniaturization. Sub-micron features allow the reduction in performance degrading capacitances and resistances to be realized. In addition the smaller features result in a smaller chip, however still possessing the same level of integration obtained for semiconductor chips fabricated with larger features. This allows a greater number of the denser, smaller chips to be obtained from a specific size starting substrate, thus resulting in a lower manufacturing cost for an individual chip.
The use of smaller, or sub-micron, features, when used for the fabrication of dynamic random access memory, (DRAM), devices, in which the capacitor of the DRAM device is a stacked capacitor, (STC), structure, presents difficulties when attempting to increase STC capacitance. A DRAM cell is usually comprised of the STC structure, overlying a transfer gate transistor, and connected to the source of the transfer gate transistor. However the decreasing size of the transfer gate transistor, limits the dimensions of the STC structure. To increase the capacitance of the STC structure, comprised of two electrodes, separated by a dielectric layer, either the thickness of the dielectric layer has to be decreased, or the area of the capacitor has to be increased. The reduction in dielectric thickness is limited by increasing reliability and yield risks, encountered with ultra thin dielectric layers. In addition the area of the STC structure is limited by the area of the underlying transfer gate transistor dimensions. The advancement of the DRAM technology to densities of 64 million cells per chip, or greater, has resulted in a specific cell in which a smaller transfer gate transistor is being used, resulting in less of an overlying area for placement of overlying STC structures.
One method of maintaining, or increasing STC capacitance, while still decreasing the lateral dimension of the capacitor, has been the use of rough, or hemispherical grain, (HSG), silicon layers. For example Thakur et al, in U.S. Pat. No. 5,656,531, describe a process for forming an HSG silicon layer, on a capacitor storage node structure, however this invention does not provide a surface preparation, applied to the storage node shape, prior to deposition of the amorphous silicon layer used for HSG formation. The absence of a pre-clean, prior to amorphous silicon deposition can result in poor adhesion between the amorphous silicon layer and the storage node shape. Zahurak et al, in U.S. Pat. No. 5,639,685, do show the use of a pre-clean procedure, however this pre-clean step is applied prior to the deposition of the polysilicon layer, used for the storage node shape, not prior to the deposition of the amorphous silicon layers, used for HSG formation. This invention will describe a process for increasing the surface area of a storage node structure, and thus the capacitance of the DRAM capacitor, via the use of an HSG layer on a patterned polysilicon storage node structure. However this invention will feature a pre-clean sequence, used prior to a deposition of a heavily doped amorphous silicon layer, on the patterned polysilicon storage node structure. The use of a heavily doped amorphous layer, prevents silicon migration. In addition native oxide formation, at the interface between HSG and the underlying silicon stack, can lead to HSG peeling. The a pre-clean procedures, followed by the deposition of a heavily doped silicon layer, prior to HSG formation, retards the native oxide growth, thus reducing the risk of peeling, or of poor adhesion of the HSG layer, to the underlying stack. This invention also features a subsequent deposition of a lightly doped, or undoped, amorphous silicon layer, and a subsequent seeding/anneal procedure, performed in situ, in the same furnace used to deposit the heavily doped amorphous silicon layer, resulting in the formation of a roughened HSG surface. In addition this invention will describes a storage node structure, intentionally designed with a narrow width, to accommodate the additional amorphous silicon layers, thus avoiding shorts between rows of tightly packed capacitor structures.
Summary of the Invention
It is an object of this invention to increase the surface area of a stacked capacitor structure, for a DRAM device, via the use of a storage node electrode, featuring a top surface comprised of HSG silicon.
It is another object of this invention to perform a dilute hydrofluoric, (DHF), acid pre-clean procedure, on a polysilicon storage node shape, prior to deposition of amorphous silicon layers, to improve the adhesion of a subsequent HSG silicon layer, to an underlying polysilicon storage node shape.
It is still another object of this invention to deposit a thin, heavily doped amorphous silicon layer, on the DHF pre-cleaned, polysilicon storage node shape, followed by an in situ deposition of a lightly doped amorphous silicon layer.
It is still yet another object of this invention to perform a seeding/annealing procedure, in situ, after deposition of the lightly doped, amorphous silicon layer, forming an HSG silicon layer from the underlying, lightly doped amorphous silicon layer.
In accordance with the present invention a method for forming an HSG silicon layer, on the top surface of a storage node shape, has been developed, featuring a process sequence comprised of an acid pre-clean procedure, followed by a deposition of a thin heavily doped amorphous silicon layer, and an in situ deposited layer of a lightly doped amorphous silicon layer, and than followed by in situ seeding/annealing procedures. A transfer gate transistor comprised of: a thin gate insulator; an insulator capped, polysilicon gate structure, a lightly doped source/drain region; insulator spacers on the sides of the polysilicon gate structure; and a heavily doped source/drain region; is formed on a semiconductor substrate. An insulator layer, is next deposited, planarized, and followed by the opening of a storage node contact hole in the insulator layer, made to expose the source region of the transfer gate transistor. Polysilicon storage node shapes are formed, completely filling the storage node contact hole, and with a portion of the polysilicon storage node shapes overlying the top surface of the insulator layer. After a DHF pre-clean procedure, a thin, heavily doped amorphous silicon layer is deposited, followed by the in situ deposition of a lightly doped amorphous silicon layer. In situ annealing/seeding procedures, performed in the same furnace used to deposit the amorphous silicon layers, is next used to convert the lightly doped amorphous silicon layer to a roughened surface, HSG silicon layer. A capacitor dielectric layer is next formed on the HSG silicon surface, followed by the deposition of an overlying polysilicon layer. A patterning procedure is than applied to the overlying polysilicon layer, creating an upper electrode shape, for the STC structures. The patterning procedure is continued by etching of the capacitor dielectric layer, etching of the HSG silicon layer, and etching of the thick, heavily doped amorphous silicon layer, creating the storage node electrode structures, for the DRAM stack capacitor structure.
Brief Description of the Drawings
The object and other advantages of this invention are best explained in the preferred embodiment with reference to the attached drawings that include:
FIGS. 1-7, which schematically, in cross-sectional style, show the key fabrication stages used to create a a STC structure for a DRAM device, in which the top surface of a storage node electrode is comprised with a roughened HSG silicon layer.
Description of the Preferred Embodiments
The method of forming an STC structure, for a DRAM device, featuring a roughened HSG silicon layer, on the top surface of a storage node electrode, used to increase the surface area, and the capacitance of the STC structure, will now be described in detail. The transfer gate transistor, used for this DRAM device, in this invention, will be an N channel device. However the STC structure, with the increased surface area described in this invention, can also be applied to P channel, transfer gate transistor.
Referring to FIG. 1, a P type, semiconductor substrate 1, with a <100>, single crystalline orientation, is used. Field oxide, (FOX), regions 2, used for isolation purposes, are formed via thermal oxidation procedures, using a patterned oxidation resistant mask, such as a silicon nitride--silicon oxide composite insulator layer, to protect subsequent device regions from the oxidation procedure. After formation of FOX regions 2, at a thickness between about 2000 to 5000 Angstroms, the composite insulator layer is removed, using hot phosphoric acid for silicon nitride, while a buffered hydrofluoric acid solution is used for the underlying silicon oxide layer. After a series of wet cleans, a gate insulator layer 3, of silicon oxide is thermally grown in an oxygen-steam ambient, at a temperature between about 750.degree. to 1050.degree. C., to a thickness between about 40 to 200 Angstroms. A polysilicon layer 4, is next deposited using low pressure chemical vapor deposition, (LPCVD), procedures, at a temperature between about 500.degree. to 700.degree. C., to a thickness between about 500 to 4000 Angstroms. The polysilicon can either be grown intrinsically and doped via ion implantation of arsenic or phosphorous, at an energy between about 10 to 80 KeV, and using a dose between about 1E13 to 1E16 atoms/cm.sup.2, or the polysilicon layer can be grown using in situ doping procedures, via the incorporation of either arsine or phosphine to a silane/disilane ambient. If desired a polycide, (metal silicide--polysilicon), can be used in place of polysilicon layer 4, to lower the resistance of the word line. This can be accomplished using either a tungsten silicide layer, or a titanium silicide layer, on an underlying polysilicon layer. A first insulator layer 5, comprised of silicon oxide, used as a cap insulator layer, is next grown via the use of either LPCVD or plasma enhanced chemical vapor deposition, (PECVD), procedures to a thickness between about 600 to 2000 Angstroms. First insulator layer 5, can also be a silicon nitride layer, again deposited using LPCVD or PECVD procedures, to a thickness between about 600 to 2000 Angstroms. Conventional photolithographic and reactive ion etching, (RIE), procedures, using CHF.sub.3 as an etchant for first insulator layer 5, and using Cl.sub.2 as an etchant for polysilicon layer 4, are used to create the polysilicon gate structure, comprised of polysilicon layer 4, with overlying capping, first insulator layer 5, shown schematically in FIG. 1. Photoresist removal is accomplished via plasma oxygen ashing and careful wet cleans.
A lightly doped source/drain region 6, is next formed via ion implantation of phosphorous, at an energy between about 5 to 60 KeV, at a dose between about 1E13 to 1E15 atoms/cm.sup.2. A second insulator layer, comprised of silicon oxide, is then deposited using either LPCVD or PECVD procedures, at a temperature between about 400.degree. to 850.degree. C., to a thickness between about 1500 to 4000 Angstroms, followed by an anisotropic RIE procedure, using CHF.sub.3 as an etchant, creating insulator spacers 7, on the sides of the polysilicon/polycide gate structure. Insulator spacers 7, can also be comprised of silicon nitride. A heavily doped source/drain region 8, is then formed via ion implantation of arsenic, at an energy between about 30 to 100 KeV, at a dose between about 1E14 to 5E16 atoms/cm.sup.2. The result of these steps are also shown schematically in FIG. 1.
A third insulator layer 20, comprised of either silicon oxide, boro-phosphosilicate glass, (BPSG), or phosphosilicate glass, (PSG), is next deposited, using LPCVD or PECVD procedures, at a temperature between about 600.degree. to 800.degree. C., to a thickness between about 3000 to 10000 Angstroms. Third insulator layer 20, is grown using tetraethylorthosilicate, (TEOS) as a source with the addition of either diborane and phosphine, for the BPSG layer, or the addition of only phosphine, for the PSG layer. Third insulator layer 20, is then planarized using chemical mechanical polishing, to provide a smoother surface for subsequent depositions and patterning procedures. Conventional photolithographic and RIE procedures, using CHF.sub.3 as an etchant, are used to open storage node contact hole 9, in third insulator layer 20, exposing the top surface of heavily doped source/drain region 8. Photoresist removal is performed via use of plasma oxygen ashing and careful wet cleans. The result of these procedures are again schematically shown in FIG. 1.
Referring to FIG. 2, a polysilicon silicon layer is deposited, via LPCVD procedures, at a temperature between about 500.degree. to 700.degree. C., to a thickness between about 1000 to 10000 Angstroms, completely filling storage node contact hole 9. The polysilicon layer is deposited using an in situ doping procedure, via the addition of arsine or phosphine, to a silane ambient. Photolithographic and RIE procedures, using Cl.sub.2 as an etchant, are used to pattern the polysilicon layer, creating polysilicon storage node shapes 10a, in storage node contact hole 9, and a neighboring polysilicon storage node shape 10b. This is schematically shown in FIG. 2. The width of the polysilicon storage node shapes, is designed to be narrower than the desired final width of a storage node electrode, to accommodate the additional amorphous silicon layers, that will subsequently reside on the sides of polysilicon storage node shapes 10a, and 10b. The space 30a, between polysilicon storage node shapes, at this stage of the process is between about 1500 to 4000 Angstroms. Removal of the masking photoresist shape, used to define polysilicon storage node shapes 10a, and 10b, is accomplished via plasma oxygen ashing and careful wet cleans.
A critical pre-clean procedure, using a dilute hydrofluoric, (DHF), acid solution, using 1 part HF, to between about 100 to 200 parts de-ionized water, at room temperature, about 25.degree. C., is next performed to remove native oxide from the surface of polysilicon storage node shapes 10a, and 10b. Next a heavily doped, amorphous silicon layer 11, is deposited in an LPCVD furnace, at a temperature between about 500.degree. to 550.degree. C., to a thickness between about 50 to 1000 Angstroms. Amorphous silicon layer 11, is in situ doped, during the LPCVD deposition, via the addition of phosphine, to a silane, or to a disilane ambient, resulting in amorphous silicon layer 11, shown schematically in FIG. 3, having a N type surface concentration greater than 4E20 atoms/cm.sup.3. The level of dopant needed for saturation is a function of the deposition temperature, and thus using the deposition temperature of 500.degree. to 550.degree. C., a dopant level, or saturation level of 4E20 atoms/cm.sup.3, or greater, resulted. The heavy doping in amorphous silicon layer 11, is needed to prevent silicon migration, that can occur during subsequent seeding/annealing cycles, subsequently used to create an HSG layer. If amorphous silicon layer 11, were lightly doped, silicon migration may have occurred. The space 30b, between polysilicon storage node shapes has now been narrowed as a result of deposition of amorphous silicon layer 11, on the sides of polysilicon storage node shapes 10a, and 10b.
Another amorphous silicon layer 12a, used as a seed layer for a subsequent HSG layer, is next in situ deposited, in the same LPCVD furnace that was used for deposition of heavily doped amorphous silicon layer 11. Amorphous silicon layer 12a, is deposited at a temperature below 550.degree. C., to a thickness between about 50 to 500 Angstroms. Amorphous silicon layer 12a, can be undoped, or it can be lightly doped, or a combination of both doped and undoped layers, with in situ doping occurring during deposition, via the incorporation of phosphine, to a silane or disilane ambient, resulting in a bulk concentration between about 0 to 4E20 atoms/cm.sup.3. This is schematically shown in FIG. 4. Space 30c, between polysilicon storage node shapes 10a, and 10b, is now further reduced, between about 1400 to 3000 Angstroms. A critical seeding/annealing procedure is next performed, in situ, in the LPCVD furnace, resulting in the formation of HSG silicon layer 12b, schematically shown in FIG. 5. First HSG seeds are formed on amorphous silicon layer 12a, using silane or disilane, in a nitrogen ambient, at a seeding concentration equal to, or less than 1.0E-3 moles/m.sup.3, at a temperature between about 550.degree. to 580.degree. C., at a pressure less than one torr, and for a time between about 5 to 120 min. Next an anneal procedure is in situ performed, in a pure nitrogen ambient, at a temperature between about 550.degree. to 580.degree. C., for a time between about 0 to 120 min, creating HSG layer 12b, schematically shown in FIG. 5. The doping supplied to HSG silicon layer 12b, from underlying amorphous silicon layer 11, prevented silicon migration from occurring during the anneal cycle. Silicon migration, if present, can interfere with the formation of HSG silicon layer 12b. The desired space 30c, between polysilicon storage node shapes, was achieved by allowing initially formed, narrow polysilicon storage node shapes, to grow to the desired width, via subsequent depositions of amorphous silicon layers. In addition the adhesion of HSG silicon layers, to polysilicon storage node structures, is improved via the inclusion of intermediate, heavily doped amorphous silicon layer 11.
A capacitor dielectric layer 13, exhibiting a high dielectric constant, such as ONO, (Oxidized--silicon Nitride--silicon Oxide), or NO, (silicon Nitride Oxidized), is next formed on HSG silicon layer 12b. The ONO layer is formed by initially growing a silicon dioxide layer, on HSG silicon layer 12b, between about 10 to 50 Angstroms, followed by the deposition of a silicon nitride layer, between about 10 to 60 Angstroms. Subsequent thermal oxidation of the silicon nitride layer results in the formation of a silicon oxynitride layer on silicon oxide, at a silicon oxide equivalent thickness of between about 40 to 80 Angstroms. This is schematically shown in FIG. 6. Finally a polysilicon layer is deposited, via LPCVD procedures, at a temperature between about 500.degree. to 700.degree. C., to a thickness between about 500 to 2000 Angstroms. Doping of polysilicon layer is accomplished via an situ doping deposition procedure, by the addition of phosphine, to the silane or a disilane ambient. Photolithographic and RIE procedures, using Cl.sub.2 as an etchant for polysilicon, are next employed to pattern the polysilicon layer, creating polysilicon upper electrode structures 14, schematically shown in FIG. 7. The patterning procedure is continued, using the same photoresist shape, (not shown in the drawings), used for definition of polysilicon upper electrode structures 14, as a mask, using CHF.sub.3 as an etchant for capacitor dielectric layer 13, and using Cl.sub.2 as an etchant for HSG silicon layer 12b, and for amorphous silicon layer 11, creating storage node electrodes 15. The DRAM, stacked capacitor structures 16, are comprised of polysilicon upper electrode structures 14, capacitor dielectric layer 13, and storage node electrodes 15, with space 30d, between about 1000 to 2000 Angstroms, now existing between stacked capacitor structures. Photoresist is again removed via plasma oxygen ashing and careful wet cleans.
While this invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of this invention.