Method for manufacturing sidewall contacts for a chalcogenide memory device

[0001] This is a division of application Ser. No. 10/331/850, filed Dec. 30, 2002.

[0002] The present invention was made under U.S. government contract No. DL-H-546317.

[0003] 1. Technical Field

[0004] The present invention relates to memory devices in general, and in particular to chalcogenide memory devices. Still more particularly, the present invention relates to a method for manufacturing sidewall contacts for a chalcogenide memory device.

[0005] 2. Description of the Prior Art

[0006] The use of phase change materials that can be electrically switched between a generally amorphous first structural state and a generally crystalline second structural state for electronic memory applications is well-known in the art. Phase change materials may also be electrically switched between different detectable states of local order across the entire spectrum between the completely amorphous and the completely crystalline states.

[0007] Some phase change materials exhibit different electrical characteristics according to their state. For example, chalcogenide materials exhibit a lower electrical conductivity in its amorphous state than it does in its crystalline state. The chalcogenide materials for making memory cells are typically compounds containing one or more elements selected from the group of tellurium, selenium, antimony, and germanium. Such chalcogenide materials can be switched between numerous electrically detectable conditions of varying resistivity in nanosecond time periods by using picojoules of energy. The resulting memory cell is truly non-volatile and will maintain the integrity of the stored information without the need for periodic signal refresh.

[0008] The operation of chalcogenide memory cells requires that a region of the chalcogenide memory material, called the chalcogenide active region, be subjected to a current pulse with a current density typically between 10⁵ and 10⁶ amperes/cm². Such current density may be accomplished by making a small pore or opening in a dielectric material that is itself deposited onto a bottom electrode material. The chalcogenide material is then deposited over the dielectric material and into the pore to contact with the bottom electrode material. A top electrode material is then deposited over the chalcogenide material. Carbon is a commonly used electrode material although other materials, such as molybdenum and titanium nitride, have also been used.

[0009] The size of the chalcogenide active region is primarily defined by the volume of chalcogenide material that is contained within the pore delineated by the opening in the dielectric material. The upper portion of the chalcogenide material not contained within the pore acts as an electrode that in turn contacts with the top electrode material. The chalcogenide active region makes contact with the bottom electrode at an interface area that is substantially equal to the cross sectional area of the pore. As a result of such configuration, the interface area of the chalcogenide material within the chalcogenide active region is subjected to the high current density required for the operation of the chalcogenide memory cell. This is an undesirable situation because the high current density at the interface area of the chalcogenide active region with the bottom electrode causes mixing of the bottom electrode material with the chalcogenide material of the chalcogenide active region due to heating and electrophoretic effects. More specifically, the mixing of the electrode material with the chalcogenide material in the chalcogenide active region causes instability of the chalcogenide memory cell during operation.

[0010] Furthermore, with current semiconductor processing technology, the minimum achievable dimension of a contact for a chalcogenide memory device is limited by lithography tools. The size of a contact, which is determined by the diameter of the pore, varies with the square of photolithography feature size error and also with the square of the variability in etch bias. Thus, step coverage also becomes an issue because aspect ratio in the pore increases as the pore diameter decreases. This leads to reduced yield, reduced reliability and reduced cycling endurance. Consequently, it is desirable to provide an improve method for manufacturing contacts for a chalcogenide memory device.

[0011] In accordance with a preferred embodiment of the present invention, a first conductive layer is initially deposited on top of a first oxide layer. The first conductive layer is then patterned and etched using well-known processes. Next, a second oxide layer is deposited on top of the first conductive layer and the first oxide layer. An opening is then etched into at least the first oxide layer such that a portion of the first conductive layer is exposed within the opening. The exposed portion of the first conductive layer is then removed from the opening such that the first conductive layer is flush with an inner surface or sidewall of the opening. After depositing a chalcogenide layer on top of the second oxide layer, filling the opening with chalcogenide, a second conductive layer is deposited on top of the chalcogenide layer.

[0012] All objects, features, and advantages of the present invention will become apparent in the following detailed written description.

[0018] Referring now to the drawings and in particular to FIG. 1, there is illustrated a block diagram of a chalcogenide memory device in which a preferred embodiment of the present invention is incorporated. As shown, a memory matrix 11 is formed on a substrate 10. Also formed on substrate 10 is an addressing matrix 12 that is suitably connected to memory matrix 11 through connections 13. Addressing matrix 12 preferably includes various signal generating means that control and read pulses applied to memory matrix 11.

[0019] With reference now to FIG. 2, there is illustrated a circuit diagram of memory matrix 11, in accordance with a preferred embodiment of the present invention. As shown, memory matrix 11 includes an x-y grid with each of memory cells 20 being connected in series with an access device 21 at the cross points of x address lines 22 and y address lines 23. Access device 21 can be a diode or a transistor. Address lines 22 and 23 are separately connected to external addressing circuitry, such as addressing matrix 12 from FIG. 1, in a manner that is well-known in the art.

[0020] FIGS. 3a-3g are pictorial representations of a process for making a sidewall contact to be used in the chalcogenide memory device from FIG. 1, in accordance with a preferred embodiment of the present invention. In FIG. 3a, a diffusion 31 is first formed within a substrate 30 using well-known masking and doping techniques. Substrate 30 may be silicon, gallium arsenide (GaAs), silicon molybdenum (SiMo) or any wafer material. Next, a dielectric layer 32 is deposited on top of substrate 30. Dielectric layer 32 may be silicon dioxide (SiO₂) or silicon nitride (SiN₂). A conventional contact (or via) 33 is formed, using well-known masking and etching techniques, within dielectric layer 32. The material sputtered inside contact 33 is preferably tungsten (W). With the current technology, the size of contact 33 is preferably around 0.25 um in diameter.

[0021] Next, a bottom electrode layer 34 is deposited on top of dielectric layer 32, as shown in FIG. 3b, using well-known masking and depositing techniques. Bottom electrode layer 34 can be a metal layer such as titanium-aluminum nitride (TiAlN) or a polysilicon layer. As shown in FIG. 3b, bottom electrode layer 34 extends from contact 33 to a location at which a sidewall contact will be built. The cross-sectional dimension (i.e., width and thickness) of bottom electrode layer 34 dictates the size of the contact area of the to-be built sidewall contact. Preferably, bottom electrode layer 34 is approximately 300 Å thick.

[0022] Then, a dielectric layer 35, which may be made of the same material as dielectric layer 32, is deposited on top of bottom electrode layer 34 and dielectric layer 32, as shown in FIG. 3c. Afterwards, a opening 36 is formed near one end of bottom electrode layer 34 within dielectric layer 32, using well-known masking and etching techniques. The diameter of opening 36 may be the same or larger than the diameter of contact 33. With the current technology, the size of opening 36 is preferably around 0.25 um in diameter.

[0023] Next, a well-known etching process is use to etch the “exposed” portion of bottom electrode layer 34 within opening 36 to form a sidewall contact 39, as shown in FIG. 3d. A metal etch having high directional etch component is preferably used to reduce undercutting of bottom electrode into the sidewall of opening 36. The size of sidewall contact 39 is the cross-sectional dimension of bottom electrode layer 34. At this point, opening 36 may be optionally etched deeper than dielectric layer 35 (i.e., deeper bottom electrode layer 34), as shown in FIG. 3d.

[0024] A chalcogenide layer 37 is then deposited on top of bottom dielectric layer 34, as shown in FIG. 3e, using well-known masking and depositing techniques. Preferably, chalcogenide layer 37 is approximately 500 Å thick. As a result of the chalcogenide depositing step, the sidewall of opening 36 is covered with chalcogenide. Hence, sidewall contact 39 is also covered with chalcogenide. Conventional masking and depositing techniques can be used to deposit chalcogenide into opening 36 because the relatively large diameter of opening 36 does not pose any step coverage problem as compared to a relatively small opening. Thus, greater adhesion is made between sidewall contact 39 and chalcogenide layer 37.

[0025] A top view of FIG. 3e is depicted in FIG. 3f. As shown, sidewall contact 39 is in touch with the chalcogenide material within opening 36. Consequently, bottom electrode layer 34 is in electrical connection with chalcogenide layer 37.

[0026] Afterwards, a top electrode layer 38 is deposited and patterned on top of chalcogenide layer 37, as shown in FIG. 3g using well-known masking and depositing techniques. Top electrode layer 38 can be a metal layer or a polysilicon layer. Finally, a dielectric layer 40 is deposited on top of top electrode layer 38 and dielectric layer 35. Dielectric layer 40 may or may not be made of the same material as dielectric layers 32 and 35.

[0027] With reference now to FIG. 4, there is depicted a high-level process flow diagram of a method for manufacturing the sidewall contact from FIGS. 3a-3g, in accordance with a preferred embodiment of the present invention. Starting at block 41, a first contact is formed within a first oxide layer on a substrate, as shown in block 42. The first contact is for contacting a diffusion contained within the substrate. Then, a first conductive layer is deposited and patterned on top of the first oxide layer, as depicted in block 43. Next, a second oxide layer is deposited on top of the first conductive layer and the first oxide layer, as shown in block 44. An opening is then etched within the second oxide layer such that a portion of the first conductive layer is exposed within the opening, as depicted in block 45. Afterwards, the exposed portion of the first conductive layer is removed from the opening by a well-known etching process such that the first conductive layer is flush with an inner surface (or sidewall) of the opening to form a sidewall contact, as shown in block 46. After depositing a chalcogenide layer on top of the second oxide layer, and filling the opening with chalcogenide material, as depicted in block 47, a second conductive layer is deposited and patterned on top of the chalcogenide layer, as shown in block 48.

[0028] As has been described, the present invention provides an improved method for manufacturing sidewall contacts for a chalcogenide memory device.

[0029] While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.