U.S. patent application number 13/326499 was filed with the patent office on 2012-05-17 for method of manufacturing semiconductor device.
This patent application is currently assigned to Kabushiki Kaisha Toshiba. Invention is credited to Isao Kamioka, Ryu Kato, Yoshio Ozawa, Junichi Shiozawa.
Application Number | 20120122294 13/326499 |
Document ID | / |
Family ID | 41117873 |
Filed Date | 2012-05-17 |
United States Patent
Application |
20120122294 |
Kind Code |
A1 |
Kamioka; Isao ; et
al. |
May 17, 2012 |
METHOD OF MANUFACTURING SEMICONDUCTOR DEVICE
Abstract
In one embodiment, a method of manufacturing a semiconductor
device includes successively forming first and second films to be
processed on a semiconductor substrate. The method further includes
removing a predetermined region of the second film by etching, to
form a slit part including sidewall parts and a bottom part, the
sidewall parts including side surfaces of the second film, and the
bottom part including an upper surface of the first film. The
method further includes supplying oxidizing ions or nitriding ions
contained in plasma, generated by a microwave, a radio-frequency
wave, or electron cyclotron resonance, to the sidewall parts and
the bottom part of the slit part by applying a predetermined
voltage to the semiconductor substrate, thereby performing
anisotropic oxidation or anisotropic nitridation of the sidewall
parts and the bottom part of the slit part.
Inventors: |
Kamioka; Isao; (Hopewell
Junction, NY) ; Shiozawa; Junichi; (Yokohama-Shi,
JP) ; Kato; Ryu; (Yokohama-Shi, JP) ; Ozawa;
Yoshio; (Yokohama-Shi, JP) |
Assignee: |
Kabushiki Kaisha Toshiba
Tokyo
JP
|
Family ID: |
41117873 |
Appl. No.: |
13/326499 |
Filed: |
December 15, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12926357 |
Nov 12, 2010 |
8097503 |
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13326499 |
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12412962 |
Mar 27, 2009 |
7858467 |
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12926357 |
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Current U.S.
Class: |
438/424 ;
257/E21.19; 257/E21.546; 438/591 |
Current CPC
Class: |
H01L 29/66825 20130101;
H01L 29/7881 20130101; H01L 27/11521 20130101; H01L 21/76208
20130101 |
Class at
Publication: |
438/424 ;
438/591; 257/E21.546; 257/E21.19 |
International
Class: |
H01L 21/762 20060101
H01L021/762; H01L 21/28 20060101 H01L021/28 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 28, 2008 |
JP |
2008-85812 |
Claims
1-18. (canceled)
19. The method according to claim 21, further comprising: forming,
before forming the tunnel insulating film, plural isolation
trenches on the surface of the semiconductor substrate; burying a
first insulating film in the isolation trenches; and burying a
second insulating film in the slit part, wherein each of the
isolation trenches is formed along a first direction and includes
sidewall parts and a bottom part, and the slit part is formed along
a second direction perpendicular to the first direction and
includes the sidewall parts and the bottom part, the sidewall parts
including side surfaces of the first conductive film, the charge
block layer, and the charge storage layer, and the bottom part
including the upper surface of the tunnel insulating film.
20. (canceled)
21. A method of manufacturing a semiconductor device, the method
comprising: forming a first film to be processed, on a
semiconductor substrate; forming a second film to be processed, on
the first film; removing a predetermined region of the second film
by etching, to form a slit part including sidewall parts and a
bottom part, the sidewall parts including side surfaces of the
second film, and the bottom part including an upper surface of the
first film; and supplying oxidizing ions or nitriding ions
contained in plasma generated by a microwave, a radio-frequency
wave, or electron cyclotron resonance to the sidewall parts and the
bottom part of the slit part by applying a predetermined voltage to
the semiconductor substrate, thereby performing anisotropic
oxidation or anisotropic nitridation of the sidewall parts and the
bottom part of the slit part, wherein the first film comprises a
tunnel insulating film formed on a surface of the semiconductor
substrate, and the second film comprises a charge storage layer, a
charge block layer, and a first conductive film as a control gate
electrode, which are sequentially formed on an upper surface of the
tunnel insulating film.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of
priority from the prior Japanese Patent Application No. 2008-85812,
filed on Mar. 28, 2008, the entire contents of which are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method of manufacturing a
semiconductor device.
[0004] 2. Background Art
[0005] Conventionally, a semiconductor device is manufactured, for
example, through the following process. A tunnel insulating film, a
polysilicon layer doped with impurities for a floating gate
electrode, a stopper film for CMP (Chemical Mechanical Polishing),
and a mask film for RIE (Reactive Ion Etching) are sequentially
deposited on the surface of a semiconductor substrate, which is
doped with desired impurities.
[0006] The mask film, the stopper film, the polysilicon layer, and
the tunnel insulating film are sequentially etched by RIE.
Furthermore, an exposed region of the semiconductor substrate is
etched to form an isolation trench.
[0007] A silicon oxide film is formed on the exposed surface of the
semiconductor substrate by thermal oxidation, and another silicon
oxide film is further deposited on the entire surface, to
completely bury the silicon oxide film in the isolation trench. The
silicon oxide film and the mask film are removed by CMP to
planarize the surface, to make the surface of the stopper film be
exposed.
[0008] After selectively removing the stopper film by etching, the
exposed surface of the silicon oxide film is etched using a diluted
hydrofluoric acid solution, to make the sidewall surfaces of the
polysilicon layer be exposed.
[0009] After an inter electrode insulating film with a three-layer
structure including a silicon oxide film, a silicon nitride film,
and a silicon oxide film is deposited on the entire surface, a
conductive layer with a two-layer structure including a polysilicon
layer and a tungsten silicide layer is deposited, and a mask film
for RIE is then deposited. The conductive layer is to be etched to
form a control gate electrode. In this specification, layers in
each multi-layer structure are described in order from the lowest
layer to the highest layer.
[0010] The mask film, the conductive layer, the inter electrode
insulating film, and the polysilicon layer are sequentially etched
by RIE, to form a slit part between stacked cells, the slit part
extending in a direction perpendicular to the isolation trench.
Thereby, the shapes of the floating gate electrode and the control
gate electrode are determined.
[0011] After forming a silicon oxide film on the exposed surface by
thermal oxidation as an electrode sidewall oxide film, a cell
diffusion layer is formed, and a silicon oxide film is then formed
as an inter layer dielectric so as to cover the entire surface.
Subsequently, an interconnect layer and the like are formed to
complete nonvolatile memory cells. However, this manufacturing
method has the following problems. [0012] (a) As nonvolatile memory
cells become finer, the reliability of the memory cells will be
significantly lowered due to the cell width (channel width) in the
word-line direction (channel-width direction) becoming smaller.
Accordingly, if oxidation performed for mending RIE process damage
before filling the isolation trenches with the silicon oxide film
is performed by isotropic oxidation such as thermal oxidation, the
cell width becomes excessively small, lowering the reliability of
the memory cells. Concurrently, the dopant concentration is lowered
due to the dopant in the channel regions being drawn into the oxide
film as a result of thermal oxidation of the sidewalls of the
semiconductor substrate, causing erroneous writing in the memory
cells.
[0013] Also, where the memory cells become finer, resulting in a
decrease in the isolation trench width, if the isolation trenches
are substantially completely filled with an insulating film,
parasitic capacitances between adjacent elements cannot be ignored
because they may cause erroneous memory operation, which is what is
called "inter-cell interference". Accordingly, it is necessary to
provide cavities in the isolation trenches. However, in case that
an insulating film is provided into the isolation trenches by means
of deposition, it is difficult to form cavities having the same
shape because of difficulty in depositing the insulating film on
the sidewall parts of the isolation trenches. [0014] (b) In
nonvolatile memory cells, when a polysilicon layer is processed by
RIE to form floating gate electrodes, the lower end parts of the
floating gate electrodes are formed in a pointed shape, locally
generating a high electric field during writing/erasing operation
for the memory cells, resulting in lowering the reliability of the
memory cells. Therefore, the locally-generated high electric field
is reduced by forming a silicon oxide film, which is an electrode
sidewall oxide film, by thermal oxidation to increase the distance
between the lower end part of each floating gate electrode and the
semiconductor substrate surface and also increase the curvature of
the lower end parts of the floating gate electrodes. However, as
the memory cells become finer, the oxidation amount in the sidewall
parts of the floating gate electrodes, which are formed by thermal
oxidation, cannot be ignored and the cell width (channel length) in
the bit-line direction (channel-length direction) becomes
excessively small, making the control of the memory cell
characteristics difficult, causing erroneous memory operation.
[0015] Furthermore, as the memory cells become finer, when a
polysilicon layer is processed by RIE to form floating gate
electrodes, there is a tendency that the width of the floating gate
electrodes becomes wider toward their lower parts (i.e., has what
is called a skirt shape). Accordingly, the lower end parts of the
floating gate electrodes are formed in a sharply pointed shape,
which is a factor promoting the lowering of the cell reliability.
[0016] (c) Transistor elements also have a problem similar to
problem (b), which is a factor of lowering the transistor
reliability. [0017] (d) In nonvolatile memory cells, when the
control gate electrodes are formed by a metal, a metal silicide or
a metal nitride such as tungsten silicide, nickel silicide, cobalt
silicide, tungsten, tantalum, titanium, tungsten nitride, tantalum
nitride or titanium nitride, the following problems are caused. A
mask film, a conductive layer, an inter electrode insulating film
and a polysilicon layer are sequentially processed by RIE to form
slit parts between the stacked cells, thereby determining the
shapes of the floating gate electrodes and the control gate
electrodes. When a silicon oxide film, which is called an electrode
sidewall oxide film, is formed on the exposed surface by thermal
oxidation, oxidation of the metal, the metal silicide or the metal
nitride are accelerated, causing a problem in a decrease in
conductivity of the control gate electrodes. Also, expansion caused
by oxidation has adverse effects on the subsequent diffusion layer
formation process by ion implantation. [0018] (e) Also, transistor
elements using a metal, a metal silicide or a metal nitride for
gate electrodes have a problem similar to that of the nonvolatile
memory cells described in (d) above. [0019] (f) In nonvolatile
memory cells, where the inter electrode insulating film is formed
of a high-permittivity metal oxide film containing oxygen, such as
alumina, hafnia, zirconia, aluminum silicate, hafnium silicate or
zirconium silicate instead of the three-layer structure consisting
of a silicon oxide film, a silicon nitride film and a silicon oxide
film, the following problem is caused. When, in the process of
forming a silicon oxide film, which is called an electrode sidewall
oxide film, on the exposed surface by thermal oxidation after
sequentially processing the mask film, the conductive layer, the
inter electrode insulating film and the polysilicon layer by RIE to
form slit parts between the stacked cells, thereby determining the
shapes of the floating gate electrodes and the control gate
electrodes, the thermal oxidation is performed in an atmosphere
including a reducing gas such as a hydrogen gas, a reaction to
abstract oxygen from the inter electrode insulating film occurs,
causing deterioration in the insulation property of the inter
electrode insulating film. [0020] (g) In some nonvolatile memories,
peripheral transistors are formed on a planar part of a
semiconductor substrate and memory cells are formed on a partial
SOI (Silicon on Insulator) substrate of the same semiconductor
substrate. In such a case, a step part is formed at the boundary
between the planar part and the partial SOI substrate by etching.
Conventionally, both the planar part and a sidewall providing the
step part are then oxidized by thermal oxidation.
[0021] Subsequently, even though the sidewall oxide film is removed
by etching, the position of the step part is displaced as a result
of oxidation and etching. This position corresponds to the boundary
between the peripheral transistors and the memory cells, and is
used as a reference for pattern formation. Consequently,
displacement of this position causes pattern displacement.
[0022] A conventional nonvolatile memory cell manufacturing method
is disclosed in, for example, JP-A 2006-222203 (KOKAI).
SUMMARY OF THE INVENTION
[0023] An aspect of the present invention is, for example, a method
of manufacturing a semiconductor device, the method including
forming, on a surface of a semiconductor substrate, an isolation
trench including sidewall parts and a bottom part, or a stepped
structure including a first planar part, a second planar part, and
a step part located at a boundary between the first planar part and
the second planar part, and supplying oxidizing ions or nitriding
ions contained in plasma generated by a microwave, a
radio-frequency wave, or electron cyclotron resonance to the
sidewall parts and the bottom part of the isolation trench or the
first and second planar parts and the step part of the stepped
structure by applying a predetermined voltage to the semiconductor
substrate, to perform anisotropic oxidation or anisotropic
nitridation of the sidewall parts and the bottom part of the
isolation trench or the first and second planar parts and the step
part of the stepped structure.
[0024] Another aspect of the present invention is, for example, a
method of manufacturing a semiconductor device, the method
including forming a gate insulation film on a semiconductor
substrate, forming a conductive film as a material for a gate
electrode, on the gate insulation film, etching the conductive film
to form the gate electrode including sidewall parts, and make a
part of a surface of the gate insulation film be exposed, and
supplying oxidizing ions or nitriding ions contained in plasma
generated by a microwave, a radio-frequency wave, or electron
cyclotron resonance to the sidewall parts of the gate electrode and
a region where the gate insulation film is exposed, by applying a
predetermined voltage to the semiconductor substrate, to perform
anisotropic oxidation or anisotropic nitridation of the sidewall
parts of the gate electrode and the region where the gate
insulation film is exposed.
[0025] Another aspect of the present invention is, for example, a
method of manufacturing a semiconductor device, the method
including forming a first film to be processed, on a semiconductor
substrate, forming a second film to be processed, on the first
film, removing a predetermined region of the second film by
etching, to form a slit part including sidewall parts and a bottom
part, the sidewall parts including side surfaces of the second
film, and the bottom part including an upper surface of the first
film, and supplying oxidizing ions or nitriding ions contained in
plasma generated by a microwave, a radio-frequency wave, or
electron cyclotron resonance to the sidewall parts and the bottom
part of the slit part by applying a predetermined voltage to the
semiconductor substrate, to perform anisotropic oxidation or
anisotropic nitridation of the sidewall parts and the bottom part
of the slit part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is an explanatory diagram showing an arrangement of a
manufacturing equipment in performing anisotropic oxidation or
anisotropic nitridation, which is to be used in manufacturing a
semiconductor device according to first to ninth embodiments;
[0027] FIGS. 2 to 9 are longitudinal cross sectional views showing
a method of manufacturing a semiconductor device according to a
first embodiment;
[0028] FIGS. 10 and 11 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to comparative example 1 for the first embodiment;
[0029] FIGS. 12 and 13 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to modification 1 for the first embodiment;
[0030] FIGS. 14 and 15 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to comparative example 2 for the first embodiment;
[0031] FIG. 16 is a longitudinal cross sectional view showing a
method of manufacturing a semiconductor device according to a
second embodiment;
[0032] FIG. 17 is a longitudinal cross sectional view showing a
method of manufacturing a semiconductor device according to
comparative example 3 for the second embodiment;
[0033] FIG. 18 is a longitudinal cross sectional view showing a
method of manufacturing a semiconductor device according to
modification 2 for the second embodiment;
[0034] FIG. 19 is a longitudinal cross sectional view showing a
method of manufacturing a semiconductor device according to
comparative example 4 for modification 2 for the second
embodiment;
[0035] FIGS. 20 to 23 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to a third embodiment;
[0036] FIG. 24 is a longitudinal cross sectional view showing a
method of manufacturing a semiconductor device according to a
fourth embodiment;
[0037] FIGS. 25 to 28 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to a fifth embodiment;
[0038] FIGS. 29 to 32 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to a sixth embodiment;
[0039] FIGS. 33 to 37 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to a seventh embodiment;
[0040] FIGS. 38 to 43 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to an eighth embodiment; and
[0041] FIGS. 44 to 47 are longitudinal cross sectional views
showing a method of manufacturing a semiconductor device according
to a ninth embodiment.
DESCRIPTION OF THE EMBODIMENTS
[0042] Embodiments of a method of manufacturing a semiconductor
device according to the present invention will be described with
reference to the drawings.
[0043] In the embodiments described below, a semiconductor device
is manufactured using anisotropic oxidation or anisotropic
nitridation. As illustrated in FIG. 1, a semiconductor substrate 1
is mounted on a stage 2. A predetermined radio-frequency voltage V
is applied from a power supply 3 to the stage 2, thereby the
radio-frequency voltage being applied to the semiconductor
substrate 1.
[0044] When plasma 4 is generated by at least any one of
microwaves, radio-frequency waves and electron cyclotron resonance
after introducing an oxygen-containing gas above the semiconductor
substrate 1 in this state, oxidizing ions, oxidizing neutral
radicals, electrons, etc., are generated. Here, the oxidizing ions
include, e.g., positively- or negatively-charged oxygen molecules
(O.sub.2), oxygen atoms (O) and ozone (O.sub.3). Alternatively,
where a nitrogen-containing gas is introduced together with the
oxygen-containing gas, the oxidizing ions also include, e.g.,
positively- or negatively-charged nitrogen monoxide molecules (NO)
and nitrous oxide molecules (N.sub.2O). Then, by properly selecting
the absolute value of the radio-frequency voltage V applied to the
semiconductor substrate 1, these oxidizing ions contained in the
plasma 4 are accelerated toward the semiconductor substrate 1, and
substantially perpendicularly enter the surface of the
semiconductor substrate 1.
[0045] Here, a large amount of oxidizing ions is supplied to the
parts parallel to the surface of the semiconductor substrate 1, and
a relatively small amount of oxidizing ions is supplied to the area
perpendicular to the surface of the semiconductor substrate 1.
Consequently, anisotropic oxidation in which the parts parallel to
the surface of the semiconductor substrate 1 has a large amount of
oxidation and the parts perpendicular to the surface of the
semiconductor substrate 1 has a relatively small amount of
oxidation can be provided.
[0046] Similarly, plasma 4 is generated by at least any one of
microwaves, radio-frequency waves and electron cyclotron resonance
after introducing a nitrogen-containing gas above the semiconductor
substrate 1, nitriding ions, nitriding neutral radicals, electrons,
etc., are generated. Here, the nitriding ions include, e.g.,
positively- or negatively-charged nitrogen molecules (N.sub.2) and
nitrogen atoms (N). Alternatively, where an oxygen-containing gas
is introduced together with the nitrogen-containing gas, the
nitriding ions also include, e.g., positively- or
negatively-charged nitrogen monoxide molecules (NO) and nitrous
oxide molecules (N.sub.2O). Then, by properly selecting the
absolute value of the radio-frequency voltage V applied to the
semiconductor substrate 1, these nitriding ions contained in the
plasma 4 are accelerated toward the semiconductor substrate 1 and
substantially perpendicularly enter the surface of the
semiconductor substrate 1.
[0047] Here, a large amount of nitriding ions is supplied to the
parts parallel to the surface of the semiconductor substrate 1, and
a relatively small amount of nitriding ions is supplied to the
parts perpendicular to the semiconductor substrate 1. Consequently,
anisotropic nitridation in which the parts parallel to the surface
of the semiconductor substrate 1 has a large amount of nitridation
and the parts perpendicular to the surface of the semiconductor
substrate 1 has a relatively small amount of nitridation can be
provided.
[0048] In the above-described anisotropic oxidation or anisotropic
nitridation, it is desirable that the pressure in the region in
which the plasma 4 is generated should be, for example, 2 kPa or
less. A lower pressure, which provides a higher ratio of generation
of oxidizing ions or nitriding ions, is desirable because more
conspicuous anisotropic oxidation or anisotropic nitridation can be
provided. Furthermore, it is desirable that the pressure of the
supply path of oxidizing ions or nitriding ions should be lowered
to, for example, 2 kPa or less because the mean free path of the
oxidizing ions or nitriding ions is lengthened, and accordingly,
even where deep trenches are formed in the semiconductor substrate
1, a sufficient amount of oxidizing ions or nitriding ions can be
supplied to the bottom parts of the trenches. Also, the temperature
of the semiconductor substrate 1 can be set within the range of,
for example, room temperature to around 800.degree. C. Here, it is
desirable that the temperature of the semiconductor substrate 1
should be, for example, 300.degree. C. or more because it enhances
the insulation property of the oxide film or nitride film to be
formed and enables reduction of formation time.
(1) FIRST EMBODIMENT
[0049] A method of manufacturing a semiconductor device according
to a first embodiment of the present invention will be described.
The first embodiment corresponds to an example of applying the
present invention to a nonvolatile memory.
[0050] First, as illustrated in FIG. 2, after forming a tunnel
insulating film 11 with a thickness of 10 nm on the surface of a
silicon substrate 1 doped with a desired impurity, by thermal
oxidation, a polysilicon layer 12 with a thickness of 150 nm, the
polysilicon layer 12 being doped with phosphorus and becoming
floating gate electrodes, a stopper film 13 used for CMP (Chemical
Mechanical Polishing), and a mask film 14 used for performing RIE
(Reactive Ion Etching) are sequentially deposited by
reduced-pressure CVD (Chemical Vapor Deposition).
[0051] Next, RIE using a resist mask (not shown), the mask film 14,
the stopper film 13, the polysilicon layer 12 and the tunnel
insulating film 11 are sequentially etched. Furthermore, exposed
regions of the semiconductor substrate 1 are etched, and as
illustrated in FIG. 3, isolation trenches 15 (only one of which is
shown) with a depth of 150 nm, each isolation trench 15 having
sidewall parts and a bottom part are formed.
[0052] Next, as illustrated in FIG. 4, a silicon oxide film is
formed on the part of the semiconductor substrate 1 whose surface
is exposed in the isolation trench 15, by means of the
aforementioned anisotropic oxidation. By means of microwaves,
radio-frequency waves or electron cyclotron resonance, oxidizing
neutral radicals, oxidizing ions and electrons are generated, and a
radio-frequency voltage of, for example, 10 to 100 V is applied to
the semiconductor substrate 1 to make the oxidizing ions be
accelerated toward the surface of the semiconductor substrate 1 and
substantially perpendicularly enter the surface of the
semiconductor substrate 1.
[0053] Consequently, the bottom part of the isolation trench 15 is
selectively oxidized, forming a relatively thick silicon oxide film
21. Meanwhile, oxidation of sidewall parts 1a of the isolation
trench 15 and the sidewall parts of the floating gate electrodes 12
is suppressed, forming a relatively thin silicon oxide film 22.
Here, the silicon oxide film 21 has an average thickness of around
5 nm, and the silicon oxide film 22 has an average thickness of
around 3 nm. Here, although the silicon oxide film 22 is formed
also on the sidewall parts of the tunnel insulating film 11, the
sidewall parts of the stopper film 13 and the upper surface part of
the stopper film 13 in FIG. 4, it may not be formed on them
depending on their materials.
[0054] In the step shown in FIG. 2, the deposition of the stopper
film 13 may be omitted. In this case, in the step shown in FIG. 3,
the polysilicon layer 12 can be used as a stopper. The omission of
the deposition of the stopper film 13 makes the etching process by
RIE to be performed easier.
[0055] In conventionally-used thermal oxidation, which will be
described later, the silicon oxide film on the sidewall parts and
the silicon oxide film on the bottom part of the isolation trenches
are formed to have the substantially same thickness. More
specifically, the thermal oxidation rate varies depending on the
crystal plane orientation of the silicon substrate, and
accordingly, when an ordinary (100) substrate is used, the
thickness of the sidewall parts becomes larger by about 10 to 20%.
Meanwhile, the anisotropic oxidation according to the first
embodiment enables the thickness of the silicon oxide film 22 on
the sidewall parts to be reduced to be around half the film
thickness on the bottom part. Accordingly, process damage in the
bottom parts of the isolation trenches 15 due to RIE can be removed
with almost no reduction of the width (channel length) of the
semiconductor substrate 1 between the isolation trenches 15.
Consequently, punch-through can be effectively suppressed without
deterioration of the reliability of the memory cells.
[0056] In other words, when process damage remains, a current flows
by the influence of the surface potential, resulting in
punch-through easily occurring. However, punch-through can be
suppressed by forming the silicon oxide film 22 to be thick on the
bottom parts to remove the process damage.
[0057] Also, in a nonvolatile memory, suppression of oxidation of
the sidewall parts 1a of the semiconductor substrate 1 enables
suppression of a decrease in the dopant concentration at the
channel edges and suppression of fluctuation in a boost ratio
.beta., and consequently, erroneous memory operation can
effectively be avoided. More specifically, as a result of reducing
the thickness of the silicon oxide film 22 formed on the sidewall
parts 1a, the width of channel edge regions 1b whose dopant
concentration has been lowered due to the dopant (such as boron)
being drawn into the silicon oxide film 22.
[0058] Here, the boost ratio .beta. is approximately expressed as
follows.
.beta.=Cins/(Cins+Cch)
[0059] provided that Cins=Cipd*Ctnl/(Cipd+Ctnl),
[0060] wherein Cipd is the capacitance of the inter electrode
insulating film,
[0061] Ctnl is the capacitance of the tunnel insulating film,
[0062] Cins is the series capacitance of Cipd and Ctnl, and
[0063] Cch is the capacitance of the channel.
[0064] Furthermore, when the anisotropic oxidation according to the
first embodiment is performed under the substrate temperature of
300.degree. C. or higher, the silicon oxide films 21 and 22 exhibit
good insulation property similar to or better than that of a
conventional thermal oxide film, thereby a good breakdown
resistance of the isolation and a good reliability of the memory
cells are achieved.
[0065] Subsequently, as in ordinary manufacturing methods, as
illustrated in FIGS. 5(a) and 5(b), a silicon oxide film 31 with a
thickness of 400 nm, which is an insulating film for isolation, is
deposited on the entire surface by plasma CVD to completely fill
the isolation trench 15. Here, FIGS. 5(a), 6(a), 7(a) and 8(a)
correspond to cross-sectional views in the bit-line
(channel-length) direction, and FIGS. 5(b), 6(b), 7(b) and 8(b)
correspond to cross-sectional views in the word-line
(channel-width) direction. Also, in FIGS. 5(a) and 5(b) to 8(a) and
8(b), an illustration of the silicon oxide films 21 and 22 and the
channel edge regions 1b in FIG. 4 is omitted.
[0066] The silicon oxide film 31 and the mask film 14 at the
surface part are removed by CMP to planarize the surface. Here, the
surface of the stopper film 13 is exposed.
[0067] Next, as illustrated in FIGS. 6(a) and 6(b), after
selectively removing the exposed stopper film 13 by etching, the
exposed surface of the silicon oxide film 31 are removed by etching
using a diluted hydrofluoric acid solution to make the sidewall
parts of the polysilicon layer 12 be exposed. It is assumed that
the height of the exposed sidewall parts is 70 nm.
[0068] Next, as illustrated in FIGS. 7(a) and 7(b), an inter
electrode insulating film 32 with a thickness of 15 nm, the inter
electrode insulating film 32 having a three-layer structure
consisting of a silicon oxide film, a silicon nitride film and a
silicon oxide film is formed on the entire surface by sequentially
depositing these films by reduced-pressure CVD. Furthermore, a
conductive layer 33 with a thickness of 100 nm, the conductive
layer 33 having a two-layer structure consisting of a polysilicon
layer and a tungsten silicide layer and becoming control gate
electrodes, is formed by sequentially depositing the polysilicon
layer and the tungsten silicide layer by reduced-pressure CVD. A
mask film 34 for RIE is further deposited by reduced-pressure
CVD.
[0069] Next, by means of RIE using a resist mask (not shown), the
mask film 34, the conductive layer 33, the inter electrode
insulating film 32 and the polysilicon layer 12 are sequentially
etched to form slit parts 38 between the stacked cells.
Consequently, the shapes of the floating gate electrodes 12 and the
control gate electrodes 33 are determined. The tunnel insulating
film 11 is an example of a first film to be processed in the
present invention, and a film including the polysilicon layer 12,
the inter electrode insulating film 32, and the conductive layer 33
is an example of a second film to be processed in the present
invention.
[0070] Next, as illustrated in FIGS. 8(a) and 8(b), a silicon oxide
film 35 with a thickness of 10 nm, which is called an electrode
sidewall oxide film, is formed on the exposed surface using the
aforementioned anisotropic oxidation, and then a cell diffusion
layer 39 is formed using ion implantation. Furthermore, a silicon
oxide film 36 and a silicon oxide 37, which serve as an inter layer
dielectric, are formed by reduced-pressure CVD so as to cover the
entire surface. An interconnect layer (not shown) and the like are
formed through the subsequent process to complete nonvolatile
memory cells.
[0071] Here, FIG. 9 is a more detailed illustration of the
structure at the stage of the silicon oxide film 35 having been
formed by anisotropic oxidation in the cross-section illustrated in
FIG. 8(a). Oxidation of the sidewall parts of the floating gate
electrode 12 and the control gate electrode 33 is suppressed to
make the silicon oxide film 35a on those parts be thin, and the
upper region 35b of the tunnel insulating film 11 exposed on the
bottom region in the slit parts 38 is selectively oxidized to
effectively improve the quality of the tunnel insulating film 11
near the lower end of the floating gate electrode 12, the tunnel
insulating film having RIE damage. Consequently, the reliability of
the memory cells can be improved while suppressing a decrease in
cell width (channel length) in the bit-line direction (channel
length direction). Here, although FIG. 9 illustrates the case where
the upper region of the tunnel insulating film 11 is selectively
oxidized, regions to be selectively oxidized can be also extended
to the surface parts of the silicon substrate 1 of the slit parts,
by performing the anisotropic oxidation longer or at higher
temperature, or changing the material of the tunnel insulating film
to such a material that is easily oxidized. In this case, the
distance between the lower end parts of the floating gate
electrodes 12 and the surface of the silicon substrate 1 can be
increased, and accordingly, the electric field is reduced, enabling
further enhancement of the reliability of the memory cells.
Although in FIG. 9, the silicon oxide film 35a is formed also on
the sidewall parts of the inter electrode insulating film 32, the
sidewall parts of the mask film 34 and the upper surface part of
the mask film 34, it may not be formed on them depending on their
materials.
(2) COMPARATIVE EXAMPLE 1 FOR THE FIRST EMBODIMENT
[0072] In a method of manufacturing a semiconductor device
according to comparative example 1, silicon oxide films are formed
by isotropic thermal oxidation, which is different from the first
embodiment. Accordingly, as illustrated in FIG. 10, which
corresponds to FIG. 4 in the first embodiment, the thickness of a
silicon oxide film 122 formed on the sidewalls of a semiconductor
substrate 101a is made to be as thick as that of the silicon oxide
film 121 formed at the bottom parts of isolation trenches 15,
making the cell width (channel width) be small. Here, although in
FIG. 10, the silicon oxide film 122 is formed also on the sidewall
parts of a tunnel insulating film 11, the sidewall parts of a
stopper film 13 and the upper parts of the stopper film 13, it may
not be formed on them depending on their materials.
[0073] Furthermore, during forming the silicon oxide film 122, a
large amount of dopant in the semiconductor substrate 101a is drawn
out, and as a result, the width of the channel edges 101b having a
decreased concentration is widened, and the decrease in dopant
concentration in the channel regions causes erroneous writing in
the cells.
[0074] Furthermore, in comparative example 1, in the process
illustrated in FIG. 11, which corresponds to FIG. 9 in the first
embodiment, a silicon oxide film is formed by isotropic thermal
oxidation. Accordingly, the thickness of the silicon oxide film
135a on the sidewalls of the floating gate electrodes 12, the inter
electrode insulating film 32a and the control gate electrodes 33
are made to be as thick as that of the silicon oxide film 135b on
the bottom surface of the slit parts 38, making the cell width
(channel length) be small. Here, although in FIG. 11, the upper
layer parts of the tunnel insulating film 11 are oxidized, the
oxidation may extend to the surface parts of the silicon substrate
1 at the slit part regions depending on the material of the tunnel
insulating film. Also, the silicon oxide film 35a is formed also on
the sidewall parts of the inter electrode insulating film 32, the
sidewall parts of the mask film 34 and the upper parts of the mask
film 34, it may not be formed on them depending on their
materials.
(3) MODIFICATION 1 FOR THE FIRST EMBODIMENT
[0075] A method of manufacturing a semiconductor device according
to modification 1 for the first embodiment will be described.
Modification 1 corresponds to an example of applying the present
invention to a nonvolatile memory.
[0076] As illustrated in FIG. 12, through the process steps
illustrated in FIGS. 2 and 3 in the first embodiment, a tunnel
insulating film 11 with a thickness of 10 nm, a polysilicon layer
12 with a thickness of 150 nm, the polysilicon layer 12 being doped
with phosphorus, a stopper film 13 and a mask film 14 are
sequentially deposited by means of reduced-pressure CVD on the
surface of a semiconductor substrate 1 doped with a desired
impurity. Next, the mask film 14, the stopper film 13, the
polysilicon layer 12 and the tunnel insulating film 11 are
sequentially etched, and furthermore, the exposed regions of the
semiconductor substrate 1 are processed by RIE to form isolation
trenches 15 (only one of which is shown) with a depth of 150 nm,
each having sidewall parts and a bottom part. Here, the RIE-process
conditions are adjusted so that the width of the isolation trench
15 is decreased toward the bottom part (i.e., so that the part 1a
of the semiconductor substrate 1 protruding between the isolation
trenches 15 has a skirt shape in cross-section). Consequently, the
isolation trench 15 can easily be filled with an insulating film
for isolation.
[0077] Next, as in the first embodiment, oxidizing ions are
generated by microwaves, radio-frequency waves or electron
cyclotron resonance and a radio-frequency voltage of, for example,
10 to 100 V is applied to the semiconductor substrate 1.
[0078] Consequently, the oxidizing ions substantially
perpendicularly enter the semiconductor substrate 1. As a result,
the bottom part of the isolation trench 15 is selectively oxidized,
forming a relatively thick silicon oxide film 21. Meanwhile,
oxidation of the upper part region of sidewall parts 1a of the
isolation trench 15 and the sidewall parts of the floating gate
electrode 12 is suppressed, forming a relatively thin silicon oxide
film 22. The thickness of the silicon oxide film 22 from the upper
part region to the lower part region of the sidewall parts 1a of
the isolation trench 15 gradually increases according to the degree
of the shirt shape. Here, although in FIG. 12, the thin silicon
oxide film 22 is not formed on the sidewall parts of the tunnel
insulating film 11, it may be formed on them depending on the
material. Also, although the silicon oxide film 22 is formed also
on the sidewall parts of the stopper film 13 and the upper surface
parts of the stopper film 13, it may not be formed on them
depending on the material.
[0079] As described above, as a result of forming the silicon oxide
films 21 and 22 using anisotropic oxidation, RIE-process damage at
the bottom parts of the isolation trenches 15 can be removed with
almost no decrease in the width (channel width) of the upper part
regions of the semiconductor substrate 1 between the isolation
trenches 15 as in the first embodiment. Consequently, punch-through
can be suppressed without deterioration of the cell reliability.
Furthermore, an increase in the distance between the lower part
regions of adjacent protruding parts 1a of the semiconductor
substrate provides a punch-through suppression effect.
[0080] Also, in a nonvolatile memory, as a result of suppressing
oxidation of the sidewall parts of the protruding parts 1a,
drawing-out of the dopant from the channel edges 1b is suppressed,
enabling suppression of fluctuation in the boost ratio.
[0081] Furthermore, when the anisotropic oxidation according to the
first embodiment is performed under the substrate temperature of
300.degree. C. or higher, the silicon oxide films 21 and 22 exhibit
good insulation property similar to or better than that of a
conventional thermal oxide film, thereby a good breakdown
resistance of the isolation and a good reliability of the memory
cells are achieved.
[0082] Subsequently, as in the first embodiment, a silicon oxide
film 31, which is an insulating film for isolation, is deposited by
plasma CVD to completely fill the isolation trench 15 as
illustrated in FIGS. 5(a) and 5(b). The silicon oxide film 31 and
the mask film 14 at the surface part are removed by CMP to
planarize the surface. Consequently, the surface of the stopper
film 13 is exposed. In the cross-sections illustrated in FIGS. 5(a)
and 5(b) to 8(a) and 8(b), the protruding part 1a of the
semiconductor substrate does not have a skirt shape in cross
section. However, in modification 1, it is assumed that the
protruding part 1a has a skirt shape in cross section as described
above.
[0083] Next, as illustrated in FIGS. 6(a) and 6(b), the exposed
stopper film 13 is selectively removed by etching, and the exposed
surface of the silicon oxide film 31 is removed by etching using a
diluted hydrofluoric acid solution to make the sidewall surfaces of
the polysilicon layer 12 be exposed.
[0084] Next, as illustrated in FIGS. 7(a) and 7(b), an inter
electrode insulating film 32 with a thickness of 15 nm, the inter
electrode insulating film 32 having a three-layer structure
consisting of a silicon oxide film, a silicon nitride film and a
silicon oxide film is formed over the entire surface by
sequentially depositing these films by reduced-pressure CVD. A
conductive layer 33 with a thickness of 100 nm, the conductive
layer 33 having a two-layer structure consisting of a polysilicon
layer and a tungsten silicide layer and becoming control gate
electrodes, is formed by sequentially depositing these films by
reduced-pressure CVD. A mask film 34 for RIE is deposited by
reduced-pressure CVD.
[0085] Next, the mask film 34, the conductive layer 33, the inter
electrode insulating film 32 and the polysilicon layer 12 are
sequentially processed by RIE to form slit parts 38 between the
stacked cells.
[0086] Next, as illustrated in FIGS. 8(a) and 8(b), a silicon oxide
film 35 with a thickness of 10 nm, which is called an electrode
sidewall oxide film, is formed on the exposed surface using
anisotropic oxidation, and then a cell diffusion layer 39 is formed
using ion implantation. Furthermore, a silicon oxide film 36, which
serves an inter layer dielectric, is formed by reduced-pressure CVD
so as to cover the entire surface. Subsequently, an interconnect
layer 37, etc., is formed by known methods to complete nonvolatile
memory cells.
[0087] Here, FIG. 13 is a more detailed illustration of the
structure at the stage of the silicon oxide films 35a, 35b and 35c
having been formed by anisotropic oxidation in the cross-section
illustrated in FIG. 8(a). In modification 1, the RIE-process
conditions are adjusted so that the width of the floating gate
electrodes 12, which consist of the polysilicon layer, increases
toward the lower parts (i.e., so that the floating gate electrodes
12 have a skirt shape in cross-section), which is different from
FIG. 9 illustrating the cross-section in the first embodiment.
[0088] In this case, also, as in the first embodiment, oxidation of
the sidewall parts of the floating gate electrodes 12 and the
control gate electrodes 33 is suppressed, enabling the thickness of
the silicon oxide film 35a on these parts to be thin, and the
bottom parts of the slit parts 38 and the skirt shape parts of the
lower end parts of the floating gate electrodes 12 are selectively
oxidized, enabling the thickness of the silicon oxide films 35b and
35c on these parts to be thick. In particular, although the lower
ends of the floating gate electrodes 12 form sharp angles,
resulting in enlargement of an electric field during
writing/erasing operation for the memory cells, such electric field
enlargement can be suppressed by forming the silicon oxide film 35c
on these parts to be thick. Consequently, the reliability of the
memory cells can be improved. Here, although FIG. 13 illustrates
the case where the tunnel insulating film 11 in the slit parts 38
is entirely oxidized down to its interface with the silicon
substrate 1, only the surface parts of the tunnel insulating film
11 may be partially oxidized, by performing the anisotropic
oxidation shorter or at lower temperature, or changing the material
of the tunnel insulating film to such a material that is not easily
oxidized. Also, although the silicon oxide film 35a is formed also
on the sidewall parts of the inter electrode insulating film 32,
the sidewall parts of the mask film 34 and the upper parts of the
mask film 34, it may not be formed on them depending on their
materials.
(4) COMPARATIVE EXAMPLE 2 FOR MODIFICATION 1 FOR THE FIRST
EMBODIMENT
[0089] A method of manufacturing a semiconductor device according
to comparative example 2 for modification 1 for the first
embodiment will be described.
[0090] As illustrated in FIG. 14, in comparative example 2, silicon
oxide films 121 and 122 are formed by performing not anisotropic
oxidation, but isotropic oxidation using thermal oxidation. In this
method, the silicon oxide film 122 having a thickness substantially
equal to that of the silicon oxide film 121 on the bottom parts of
isolation trenches 15 are formed on the sidewall parts of
protruding parts 101a of a semiconductor substrate 101.
Consequently, the width of the protruding parts of the silicon
substrate becomes smaller at the bottom parts of the isolation
trenches 15, causing punch-through. Here, although in FIG. 14, the
silicon oxide film 122 is not formed on the sidewall parts of the
tunnel insulating film 11, it may be formed on them depending on
the material. Also, although the silicon oxide film 122 is formed
also on the sidewall parts of the stopper film 13 and the upper
surface parts of the stopper film 13, it may not be formed on them
depending on the material.
[0091] Also, in a nonvolatile memory, the silicon oxide film 122
having a large thickness, which is formed on the sidewall parts of
the protruding parts 101a, increases the amount of dopant drawn out
from channel edges 101b, causing fluctuation in the boost
ratio.
[0092] Furthermore, a silicon oxide film formed using thermal
oxidation exhibits a breakdown resistance lower than that of a
silicon oxide film using the anisotropic oxidation under the
substrate temperature of 300.degree. C. or higher according to the
modification of the first embodiment.
[0093] FIG. 15 illustrates a cross-sectional structure in
comparative example 2, which corresponds to the process step
illustrated in FIG. 13 in the modification of the first embodiment.
In this modification, as a result of using isotropic oxidation
instead of anisotropic oxidation, the thickness of the silicon
oxide film 135a forming the sidewall parts of the floating gate
electrodes 12 and the control gate electrodes 33 and the thickness
of the silicon oxide film 135b forming the bottom parts of slit
parts 38 are substantially equal to each other, and accordingly the
floating gate electrodes 12 and the control gate electrodes 33
become narrow. Here, although FIG. 15 illustrates the case where
the tunnel insulating film 111 in the slit parts 38 is entirely
oxidized down to its interface with the silicon substrate 1, only
the surface parts of the tunnel insulating film 111 may be
partially oxidized, depending on the material of the tunnel
insulating film. Also, although the silicon oxide film 35a is
formed also on the sidewall parts of an inter electrode insulating
film 32, the sidewall parts of a mask film 34 and the upper surface
parts of the mask film 34, it may not be formed depending on their
materials.
(5) SECOND EMBODIMENT
[0094] A method of manufacturing a semiconductor device according
to a second embodiment of the present invention will be described.
The second embodiment corresponds to an example of applying the
present invention to transistor elements.
[0095] As illustrated in FIG. 16, a gate insulation film 52 is
formed on the surface of a semiconductor substrate 51. Then,
materials for gate electrodes, for example, a polysilicon layer
doped with phosphorus, a metal compound, a metal silicide and the
like are deposited on the surface, and processed to be formed in
the shape of gate electrodes 53 (one of which is shown).
[0096] Using the anisotropic oxidation described in first
embodiment, oxidizing ions are generated by means of microwaves,
radio-frequency waves or electron cyclotron resonance, and a
radio-frequency wave voltage of, for example, 10 to 100 V is
applied to the semiconductor substrate 51. The oxidizing ions are
accelerated toward the semiconductor substrate 51 and substantially
perpendicularly enter the surface of the semiconductor substrate
51. Oxidation of the sidewalls of the gate electrode 53 is
suppressed, making a silicon oxide film 63 on these parts be thin,
and a silicon oxide film 62 on the exposed gate insulation film 52
and a silicon oxide film 61 on the gate electrode 53 are
selectively oxidized, to make their film thicknesses be large.
Here, although FIG. 16 illustrates the case where the upper parts
of the gate insulation film 52 are oxidized, the gate insulation
film may be entirely oxidized, by performing the anisotropic
oxidation longer or at higher temperature, or changing the material
of the gate insulation film to such a material that is easily
oxidized. Alternatively, the oxidation may extend to the surface
parts of the silicon substrate 51 in the exposed gate insulation
film regions.
[0097] Consequently, the reliability of the gate insulation film 52
can be improved while suppressing a decrease in the width of the
gate electrodes 53 due to the oxidation of the sidewalls of the
gate electrodes 53. In the subsequent process, an inter layer
dielectric, contact holes, an interconnect layer are formed to
complete transistor elements.
(6) COMPARATIVE EXAMPLE 3 FOR THE SECOND EMBODIMENT
[0098] A method of manufacturing a semiconductor device according
to comparative example 3 for the second embodiment will be
described.
[0099] As illustrated in FIG. 17, a gate insulation film 52 is
formed on the surface of a semiconductor substrate 51, and gate
electrodes (only one of which is shown) 53 are further formed on
the surface.
[0100] The surface and sidewalls of the gate electrode 53 and the
gate insulation film 52 are oxidized using isotropic thermal
oxidation, which is different from the anisotropic oxidation in the
first embodiment, to form silicon oxide films 161, 163 and 162
having film thicknesses equal to each other. As a result, the
sidewalls of the gate electrode 53 are oxidized, resulting in the
width of the gate electrode 53 being smaller. Here, although in
FIG. 17, the upper parts of the gate insulation film 52 are
oxidized, the entire gate insulation film may be oxidized depending
on the material of the gate insulation film. Alternatively, the
oxidation may extend to the surface parts of the silicon substrate
51 in the exposed gate insulation film regions.
(7) MODIFICATION 2 FOR THE SECOND EMBODIMENT
[0101] A method of manufacturing a semiconductor device according
to modification 2 for the second embodiment of the present
invention will be described. Modification 2 corresponds to an
example of applying the present invention to transistor
elements.
[0102] As illustrated in FIG. 18, a gate insulation film 72 is
formed on the surface of a semiconductor substrate 71. Then,
materials for gate electrodes, for example, a polysilicon layer
doped with phosphorus, a metal compound, a metal silicide and the
like are deposited on the surface, and processed by RIE so that the
width of gate electrodes 73 (only one of which is shown) increases
toward their lower parts. In other words, the gate electrode 73 is
processed so that it has a width increasing toward its interface
with the gate insulation film 72.
[0103] Using the anisotropic oxidation described in the first
embodiment oxidizing ions are generated by microwaves,
radio-frequency waves or electron cyclotron resonance, and a
radio-frequency wave voltage of, for example, 10 to 100 V is
applied to the semiconductor substrate 71. Oxidizing ions are
accelerated toward the semiconductor substrate 71 and substantially
perpendicularly enter the surface of the semiconductor substrate
71. Oxidation of the sidewalls of the gate electrode 73 is
suppressed, making the thickness of a silicon oxide film 83 on
these parts be small, and a silicon oxide film 82 on the exposed
gate insulation film 72 and a silicon oxide film 81 on the surface
of the gate electrode 73 are selectively oxidized to make their
film thicknesses be large. The thickness of the silicon oxide film
83 on the sidewall parts of the gate electrode 73 gradually
increases from the upper regions to the lower regions of the
sidewall parts of the gate electrode 73. Here, although FIG. 18
illustrates the case where the upper parts of the gate insulation
film 72 are oxidized, the gate insulation film 72 may be entirely
oxidized, by performing the anisotropic oxidation longer or at
higher temperature, or changing the material of the gate insulation
film to such a material that is easily oxidized. Alternatively, the
oxidation may extend to the surface parts of the silicon substrate
71 in the exposed regions of the gate insulation film.
[0104] Consequently, even where the width of the gate electrodes 73
increases toward their lower parts and the electric field in the
lower parts thereby increases, a decrease in the width of the gate
electrodes 73 can be suppressed, and the reliability of the gate
insulation film 72 can be enhanced notably. In the subsequent
process, an inter layer dielectric and contact holes are formed
using known methods to complete transistor elements.
(8) COMPARATIVE EXAMPLE 4 FOR MODIFICATION 2 FOR THE SECOND
EMBODIMENT
[0105] A method of manufacturing a semiconductor device according
to comparative example 4 for modification 2 for a second embodiment
of the present invention will be described. As in modification 2,
comparative example 4 relates to a transistor element manufacturing
method.
[0106] As illustrated in FIG. 19, a gate insulation film 72 is
formed on the surface of a semiconductor substrate 71. Then,
materials for gate electrodes, for example, a polysilicon layer
doped with phosphorus, a metal compound, a metal silicide and the
like are deposited on the surface, and processed by RIE so that the
width of gate electrodes 73 (only one of which is shown) increases
toward their lower parts.
[0107] Using isotropic thermal oxidation, which is different from
modification 2, a silicon oxide film 183 is formed on the sidewalls
of the gate electrode 73 and a silicon oxide film 182 is formed on
the exposed gate insulation film 72 so as to have thicknesses
substantially equal to each other by subjecting these parts to the
same degree of oxidation. Here, although in FIG. 19, the upper
regions of the gate insulation film 72 are oxidized, the entire
gate insulation film may be oxidized depending on the material of
the gate insulation film. Alternatively the oxidation may extend to
the surface parts of the silicon substrate 71 in the exposed gate
insulation film regions.
[0108] Consequently, even where the width of the gate electrodes 73
increases toward their lower parts, the width of the gate
electrodes 73 becomes small.
(9) THIRD EMBODIMENT
[0109] A method of manufacturing a semiconductor device according
to a third embodiment of the present invention will be described.
The third embodiment corresponds to an example of applying the
present invention to a nonvolatile memory, in which silicon nitride
films are formed using anisotropic nitridation.
[0110] As illustrated in FIGS. 20(a) and 20(b), through the process
steps illustrated in FIGS. 2 and 3 in the first embodiment, a
tunnel insulating film 202 with a thickness of 10 nm, a polysilicon
layer 203 with a thickness of 150 nm, the polysilicon layer 203
being doped with phosphorus, a stopper film 204 and a mask film 205
are sequentially deposited by reduced-pressure CVD on the surface
of a semiconductor substrate 201 doped with a desired impurity.
[0111] Here, FIGS. 20(a), 21(a), 22(a) and 23(a) correspond to
cross-sectional views in the bit-line (channel-length) direction,
and FIGS. 20(b), 21(b), 22(b) and 23(b) correspond to
cross-sectional views in the word-line (channel-width)
direction.
[0112] The mask film 205, the stopper film 204, the polysilicon
layer 203 and the tunnel insulating film 202 are sequentially
etched and the exposed regions of the semiconductor substrate 201
are etched to form isolation trenches 206 with a depth of 150
nm.
[0113] Next, using the above-described anisotropic nitridation,
nitriding ions are generated by microwaves, radio-frequency waves
or electron cyclotron resonance, and a radio-frequency wave voltage
of, for example, 10 to 100 V is applied to the semiconductor
substrate 201. Consequently, the nitriding ions are accelerated
toward the semiconductor substrate 201 and substantially
perpendicularly enter the semiconductor substrate 201.
Consequently, nitridation of the sidewall parts of a semiconductor
substrate 201a, which is left unprocessed in the shape of
protrusions (only one of which is shown), and a floating gate
electrode 203 is suppressed, forming a silicon nitride film 207
having a small thickness of, for example, 1 nm, and the bottom
parts of the isolation trenches 206 are selectively nitrided,
forming a silicon nitride film 208 having a large thickness of, for
example, 3 nm. Here, although in FIG. 20, the silicon nitride film
207 is formed also on the sidewall parts of the tunnel insulating
film 202, the sidewall parts of the stopper film 204, the sidewall
parts of the mask film 205 and the upper surface part of the mask
film 205, it may not be formed on them depending on their
materials.
[0114] Consequently, etching process damage in the bottom parts of
the isolation trenches 206 can be removed with almost no reduction
of the width (channel width) of the semiconductor substrate 201a
between the isolation trenches 206. As a result, punch-through can
be effectively suppressed without deterioration of the reliability
of the memory cells.
[0115] Moreover, in the process step of depositing a silicon
insulating film 209 formed of a silicon oxide film or a silicon
oxynitride film, which fills the isolation trenches 206, by means
of, e.g., CVD after removal of the mask film 205, which is
illustrated in FIGS. 21(a) and 21(b), the existence of the silicon
nitride film 208 having a large film thickness on the bottom parts
of the isolation trenches 206 enables the start time (so-called the
incubation time) for deposition on the bottom parts to be delayed
compared to the start time for deposition on the sidewall parts of
the silicon nitride film 207. As a result, the difference between
deposition thicknesses on the sidewall and bottom parts due to the
low deposition rate for the sidewall parts and the high deposition
rate for the bottom parts can be reduced, enabling depositing the
isolation insulating films conformally. Consequently, isolation
insulating films 209 having cavities 210 of the same shape around
their centers can be formed.
[0116] In the step shown in FIG. 20, the deposition of the stopper
film 204 may be omitted. In this case, in the step shown in FIG.
21, the polysilicon layer 203 can be used as a stopper. The
omission of the deposition of the stopper film 204 makes the
etching process by RIE to be performed easier.
[0117] In the subsequent process, as illustrated in FIGS. 22(a) and
22(b), the stopper film 204 is removed, and an inter electrode
insulating film 211, a conductive layer 212 and a mask film 213 are
deposited on the polysilicon film 203.
[0118] Next, by means of RIE using a resist film (not shown), the
mask film 213, the conductive layer 212, the inter electrode
insulating film 211 and the polysilicon layer 203 are sequentially
etched to form slit parts 214 between the stacked cells. The tunnel
insulating film 202 is an example of a first film to be processed
in the present invention, and a film including the polysilicon
layer 203, the inter electrode insulating film 211, and the
conductive layer 212 is an example of a second film to be processed
in the present invention.
[0119] Next, using anisotropic nitridation, nitriding ions are
generated by microwaves, radio-frequency waves or electron
cyclotron resonance, and a radio-frequency wave voltage of, for
example, 10 to 100 V is applied to the semiconductor substrate
201.
[0120] Consequently, nitriding ions are accelerated toward the
semiconductor substrate 201 and substantially perpendicularly enter
the semiconductor substrate 201, whereby nitridation of the
sidewalls of floating gate electrodes formed of the polysilicon
film 203, the inter electrode insulating film 211 and control gate
electrodes formed of the conductive layer 212 is suppressed, and
the exposed tunnel insulating film 202 is selectively nitrided.
[0121] Consequently, the silicon nitride film 217 having a small
thickness of, for example, 1 nm is formed on the sidewalls of the
slit parts 214, and the silicon nitride film 216 having a large
thickness of, for example, 3 nm is formed on the upper surface of
the tunnel insulating film 202, enabling the reliability of the
tunnel insulating film 202 to be improved while preventing
interference between adjacent cells. Here, although FIG. 22
illustrates the case where the upper regions of the tunnel
insulating film 202 are nitrided, the surface parts of the silicon
substrate 1 of the slit parts may be also nitrided, by performing
the anisotropic nitridation longer or at higher temperature, or
changing the material of the tunnel insulating film to such a
material that is easily nitrided. Also, although the silicon
nitride film 217 is formed also on the sidewall parts of the inter
electrode insulating film 211, the sidewall parts of the mask film
213 and the upper part of the mask film 213, it may not be formed
on them depending on their materials. In the subsequent process, as
illustrated in FIG. 23, a silicon oxide film 218 is formed, and
then a cell diffusion layer 221 is formed using ion implantation.
Furthermore, a silicon oxide film 219 and a silicon oxide film 220,
which serve as an inter layer dielectric, are formed by
reduced-pressure CVD so as to cover the entire surface.
Subsequently, an interconnect layer (not shown) and the like are
formed to complete nonvolatile memory cells.
[0122] According to the third embodiment, etching process damage in
the bottom parts of the isolation trenches 206 can be removed with
almost no reduction of the width (channel width) of the
semiconductor substrate 201a between the isolation trenches 206.
Consequently, punch-through can be effectively suppressed without
deterioration of the reliability of the memory cells. Moreover,
when depositing a silicon insulating film in isolation trenches, a
silicon nitride film having a large thickness is formed on the
bottom parts of the isolation trenches in advance, enabling the
start time for deposition on the bottom parts of the isolation
trenches be delayed compared to that of the sidewall parts, whereby
the difference between the thicknesses of the films deposited on
the sidewall parts and the bottom parts can be reduced, enabling
formation of isolation insulating films 209 having cavities of the
same shape around their centers. This enables to prevent
interference between adjacent cells due to a parasitic capacitance
in the word-line direction (channel width direction).
[0123] Also, according to the third embodiment, nitridation of the
sidewall parts of the floating gate electrodes and the control gate
electrodes is suppressed, enabling the reliability of the tunnel
insulating film to be enhanced while preventing the interference
between adjacent cells due to the parasitic capacitance in the
bit-line direction (channel length direction). Also, positive fixed
charge in the silicon nitride film 216 can lower the resistance of
the diffusion layer 221, increasing on-state current for the memory
cells, enabling a high-speed memory operation.
(10) FOURTH EMBODIMENT
[0124] A method of manufacturing a semiconductor device according
to a fourth embodiment of the present invention will be described.
The fourth embodiment corresponds to an example of applying the
present invention to transistor elements.
[0125] As illustrated in FIG. 24, a gate insulation film 252 is
formed on the surface of a semiconductor substrate 251, and as a
material for gate electrodes, for example, a polysilicon layer
doped with phosphorus is deposited and processed by RIE to have the
shape of gate electrodes 253 (one of which is shown).
[0126] Using anisotropic nitridation, nitriding ions are generated
by microwaves, radio-frequency waves or electron cyclotron
resonance. By applying a radio-frequency wave voltage of, for
example, 10 to 100 V to the semiconductor substrate 251, the
nitriding ions are accelerated toward the semiconductor substrate
251 and substantially perpendicularly enter the semiconductor
substrate 251.
[0127] Consequently, nitridation of the sidewall parts of the gate
electrode 253 is suppressed, making the thickness of the silicon
nitride film 263 on these parts be small, the exposed gate
insulation film 252 is selectively nitrided, making the thickness
of the silicon nitride film 262 on these parts be large.
Consequently, the reliability of the gate insulation film 252 can
be improved.
[0128] In the subsequent process, an inter layer dielectric,
contact holes and an interconnect layer are formed to complete
transistor elements.
[0129] Since the gate insulation film can be selectively nitrided
while suppressing nitridation of the gate electrode sidewall parts,
the reliability of the gate insulation film can be improved while
suppressing a decrease in the width of the gate electrodes to avoid
short channel effect. Also, reliability deterioration of transistor
elements due to stress caused by the silicon nitride film on the
gate electrode sidewall parts can be reduced.
(11) FIFTH EMBODIMENT
[0130] A method of manufacturing a semiconductor device according
to a fifth embodiment of the present invention will be described.
The fifth embodiment corresponds to an example of applying the
present invention to transistor elements. This manufacturing method
is applied to the case where a metal material with a limited
tolerable manufacturing process temperature is used for a material
for gate electrodes.
[0131] As illustrated in FIG. 25, a polysilicon film with a
thickness of, e.g., 150 nm, which becomes a dummy gate film, is
deposited by reduced-pressure CVD (Chemical Vapor Deposition) on
the surface of a semiconductor substrate 301 doped with a desired
impurity. By means of RIE using a resist mask (not shown), the
polysilicon film is etched to form a dummy gate film 302 and make
parts of the semiconductor substrate 301 be exposed.
[0132] Next, as illustrated in FIG. 26, an insulating film, such as
a silicon nitride film, for example, is deposited on the dummy gate
film 302 and processed by RIE so that an insulating film 303
remains only on the sidewalls of the dummy gate film 302.
Furthermore, after depositing an insulating film 304, CMP is
performed to planarize the surface to be at the same level as the
dummy gate film 302.
[0133] Next, as illustrated in FIG. 27, after removing the dummy
gate film 302 by etching, insulating films 305 and 306 each having
a thickness of 2 nm are formed on the entire exposed surface. Here,
the insulating film 305 is formed on the surface of the
semiconductor substrate 301 surrounded by the insulating film 303,
and serves as a gate insulation film. Also, the insulating film 306
is formed on the sidewall parts of the insulating film 303.
[0134] Furthermore, using anisotropic oxidation, oxidizing ions are
generated by means of microwaves, radio-frequency waves or electron
cyclotron resonance, and a radio-frequency wave voltage of, for
example, 10 to 100 V is applied to the semiconductor substrate 301.
The oxidizing ions are accelerated toward the semiconductor
substrate 301 and substantially perpendicularly enter the
semiconductor substrate 301, whereby the oxidation of the
insulating film 306 on the sidewall parts is suppressed, making the
film thickness be small, and the gate insulation film 305 exposed
on the bottom surface is selectively oxidized, making oxidation
reforming regions 307 (one of which is shown) on the gate
insulation film 305 have a large thickness.
[0135] In the subsequent process, as illustrated in FIG. 28, a
metal or a metal compound is deposited to form a gate electrode
308, and an inter layer dielectric, contact holes and an
interconnect layer are formed to complete transistor elements.
[0136] According to the fifth embodiment, the gate insulation film
305 is selectively oxidized while suppressing oxidation of the
sidewall parts of the insulating film 306, enabling the reliability
of the gate insulation film to be enhanced while suppressing a
decrease in the width of the gate electrodes to avoid short channel
effect. Also, it is possible to suppress oxidation of the gate
electrodes 308 due to an oxidant diffusing from the insulating film
303 and/or the insulating film 304 during the subsequent process,
because surface parts of the insulating film 306 on the sidewall
parts are oxidized by oxidizing ions.
(12) SIXTH EMBODIMENT
[0137] A method of manufacturing a semiconductor device according
to a sixth embodiment of the present invention will be described.
The sixth embodiment corresponds to an example of applying the
present invention to a nonvolatile memory.
[0138] As illustrated in FIG. 29, a silicon nitride film 302 with a
thickness of 100 nm is formed by reduced-pressure CVD on the
surface of a semiconductor substrate 301 doped with a desired
impurity, and a mask film 303 for RIE is deposited by
reduced-pressure CVD.
[0139] By means of RIE using a resist mask (not shown), the mask
film 303 and the silicon nitride film 302 are sequentially etched,
and furthermore, the exposed regions of the semiconductor substrate
301 are etched to form isolation trenches 304 with a depth of 150
nm.
[0140] Next, as illustrated in FIG. 30, a silicon oxide film with a
thickness of 5 nm (not shown) is formed by thermal oxidation on the
exposed surface of the semiconductor substrate 301. A silicon oxide
film 305 with a thickness of 400 nm, which is an insulating film
for isolation, is deposited on the entire surface by plasma CVD to
fill the isolation trenches 304. The surface parts of the silicon
oxide film 305 are removed by CMP to planarize the surface. At this
stage, the surface of the silicon nitride film 302 is exposed.
[0141] Next, as illustrated in FIG. 31, the silicon nitride film
302 is selectively etched, making parts of the surface of the
semiconductor substrate 301 be exposed.
[0142] A tunnel oxide film 306 having a thickness of 10 nm is
formed on the surface of the exposed surface of the semiconductor
substrate 301 by thermal oxidation. Furthermore, using anisotropic
nitridation, nitriding ions are generated by microwaves,
radio-frequency waves or electron cyclotron resonance, and a
radio-frequency wave voltage of, for example, 10 to 100 V is
applied to the semiconductor substrate 301. The nitriding ions are
accelerated toward the semiconductor substrate 301 and
substantially perpendicularly enter the semiconductor substrate
301. Consequently, nitridation of the sidewall parts of the silicon
oxide film 305 is suppressed, making the thickness of the silicon
nitride film 308 on these parts be small, and the tunnel oxide film
306 is selectively nitrided, making the thickness of the silicon
nitride film 307 on these parts be large. As described above, the
surface of the tunnel oxide film 306 is nitrided to form a silicon
nitride film (or silicon oxynitride film) 307.
[0143] In this embodiment, though the tunnel oxide film 306 is
formed on the surface of the exposed semiconductor substrate 301 by
thermal oxidation and then anisotropic nitridation is performed,
such sequence may be reversed, i.e., thermal oxidation may be
performed after performing anisotropic nitridation. Furthermore,
thermal annealing may be performed after performing anisotropic
nitridation. Alternatively, the thermal oxidation may be
omitted.
[0144] In the subsequent process, as illustrated in FIG. 32, a
polysilicon film 309, which serves as floating gate electrodes, is
formed, and an inter electrode insulating film 310 and control gate
electrodes 311 are formed to complete a memory cell structure.
[0145] According to the sixth embodiment, as a result of using
anisotropic nitridation, nitridation of the silicon oxide film 305
on the sidewall parts can be suppressed, enabling suppression of
interference between adjacent cells due to a parasitic capacitance
in the word-line direction (channel width direction). In
particular, where the thickness of the silicon nitride film 308 on
the sidewalls, which is illustrated in FIG. 31, is large, adjacent
cells become closer to each other, causing a phenomenon in which
they interfere with each other because of a silicon nitride film
having a high permittivity. However, such phenomenon can be
suppressed.
[0146] Also, since the surface of the tunnel insulating film 306 is
sufficiently nitrided by the anisotropic nitridation, this enables
the reliability of the tunnel insulating film to be enhanced.
(13) SEVENTH EMBODIMENT
[0147] A method of manufacturing a semiconductor device according
to a seventh embodiment of the present invention will be described.
The seventh embodiment corresponds to an example of applying the
present invention to a nonvolatile memory in which control
electrodes includes a metal layer or a metal compound layer, and an
inter electrode insulating film includes a high-permittivity metal
oxide film. In this specification, a material having a
high-permittivity means such a material that has a relative
permittivity of 7 or higher. This means that the permittivity of
the material is approximately equal to or higher than that of
silicon nitride.
[0148] Here, FIGS. 33(a), 34(a), 35(a), 36(a), 37(a) correspond to
cross-sectional views in the bit-line (channel-length) and FIGS.
33(b), 34(b), 35(b), 36(b) and 37(b) correspond to cross-sectional
views in the word-line (channel-width) direction.
[0149] A tunnel insulating film 402 with a thickness of 10 nm is
formed on the surface of a semiconductor substrate 401 doped with a
desired impurity, by thermal oxidation. A polysilicon layer 403
with a thickness of 150 nm, the polysilicon layer 403 being doped
with phosphorus and serving as floating gate electrodes, a stopper
film 404 used for CMP, and a mask film 405 used for RIE are
deposited on the tunnel insulating film 402 by reduced-pressure
CVD.
[0150] By means of RIE, the mask film 405, the stopper film 404,
the polysilicon layer 403 and the tunnel insulating film 402 are
sequentially etched. The exposed regions of the semiconductor
substrate 401 are etched to form isolation trenches 406 with a
depth of 150 nm.
[0151] Next, as illustrated in FIGS. 34(a) and 34(b), a silicon
oxide film 407 with a thickness of 400 nm, which is an insulating
film for isolation, is deposited on the entire surface by plasma
CVD to fill the isolation trenches 406 with the silicon oxide film
407. The silicon oxide film 407 and the mask film 405 are removed
by CMP to planarize the surface. Here, the surface of the stopper
film 404 is exposed.
[0152] Next, as illustrated in FIGS. 35(a) and 35(b), the exposed
stopper film 404 is selectively etched, and then the exposed
surface of the silicon oxide film 407 is removed by etching using a
diluted hydrofluoric acid solution to make the sidewall surfaces of
the polysilicon layer 403 be exposed. It is assumed that the height
of the sidewalls is 70 nm. By immersing the substrate in a diluted
hydrofluoric acid, a natural oxide film (not shown) on the surface
of the polysilicon layer 403 is removed.
[0153] Next, as illustrated in FIGS. 36(a) and 36(b), a hafnia film
is deposited in a deposition reactor as an inter electrode
insulating film 411. Although in the seventh embodiment, a hafnia
film is used for the inter electrode insulating film 411, a
high-permittivity metal oxide film with a relative permittivity of
7 or more, such as Al.sub.2O.sub.3, ZrO.sub.2, LaO.sub.2, HfSiO,
ZrSiO, HfAlO, ZrAlO or LaAlO, for example, may be formed.
[0154] A conductive layer 412 with a thickness of 100 nm, the
conductive layer 412 being having a two-layer structure of metal
compounds consisting of a polysilicon layer and a tungsten silicide
layer and becoming control gate electrodes, is formed by
sequentially depositing the polysilicon layer and the tungsten
silicide layer by reduced-pressure CVD, and a mask film 413 for RIE
is further deposited by reduced-pressure CVD.
[0155] In the seventh embodiment, the conductive layer 412, which
become control gate electrodes, have a two-layer structure
consisting of a polysilicon layer and a tungsten silicide layer.
However, it may have a single-layer structure of, e.g., cobalt
silicide (CoSi), nickel silicide (NiSi), tantalum nitride (TaN),
titanium nitride (TiN), tungsten nitride (WN), tantalum silicon
nitride (TaSiN) or titanium silicon nitride (TiSiN) or a laminate
structure consisting of any combination thereof.
[0156] Subsequently, by means of RIE using a resist mask (not
shown), the mask film 413, the conductive layer 412, the inter
electrode insulating film 411 and the polysilicon layer 403 are
sequentially etched to form slit parts 420 between the stacked
cells. The tunnel insulating film 402 is an example of a first film
to be processed in the present invention, and a film including the
polysilicon layer 403, the inter electrode insulating film 411, and
the conductive layer 412 is an example of a second film to be
processed in the present invention.
[0157] Next, as illustrated in FIGS. 37(a) and 37(b), using
anisotropic oxidation, oxidizing ions are generated from a gas
mixture of oxygen and hydrogen by microwaves, radio-frequency waves
or electron cyclotron resonance, and a radio-frequency wave voltage
of, for example, 10 to 100 V is applied to the semiconductor
substrate. Consequently, the oxidizing ions are accelerated toward
the semiconductor substrate, and substantially perpendicularly
enter the semiconductor substrate, forming a silicon oxide film 421
with a thickness of around 5 nm, which is called as an electrode
sidewall oxide film, on the exposed surface. Here, oxidation of the
sidewall parts of the polysilicon layer 413 as the floating gate
electrodes, and the sidewall parts of the conductive layer 412 as
the control gate electrodes is suppressed, enabling selective
oxidation of the exposed tunnel insulating film 402. Here, although
FIG. 37 illustrates the case where the upper regions of the tunnel
insulating film 402 are oxidized, the surface parts of the silicon
substrate 1 of the slit parts may be also oxidized, by performing
the anisotropic oxidation longer or at higher temperature, or
changing the material of the tunnel insulating film to such a
material that is easily oxidized. In this case, since the distance
between the lower end of each floating gate electrode 403 and the
surface of the silicon substrate 401 can be increased, the electric
field is reduced, enabling the reliability of the memory cells to
be further enhanced. Although in FIG. 37, the silicon oxide film
421 is formed also on the sidewall parts of the inter electrode
insulating film 411, the sidewall parts of the mask film 413 and
the upper surface part of the mask film 413, it may not be formed
on them depending on their materials.
[0158] Here, as a result of performing anisotropic oxidation using
a gas mixture of hydrogen and oxygen, oxidation of the conductive
layer 412 formed of a metal compound, which serves as control gate
electrodes, is suppressed, enabling erroneous memory operation due
to an increase in the resistance of the control gate electrodes to
be avoided. Also, where the inter electrode insulating film 411 is
formed of high-permittivity metal oxide as in this embodiment,
reduction by means of hydrogen, which results in deterioration of
the insulation property, can be suppressed. Accordingly, the
reliability of the tunnel insulating film 402 can be improved while
suppressing an increase in the electrode resistance and
deterioration of the inter electrode insulating film.
[0159] Here, although anisotropic oxidation is performed using a
gas mixture of hydrogen and oxygen, anisotropic oxidation may be
performed using an oxygen gas not containing hydrogen.
[0160] In the subsequent process, a cell diffusion layer 424 is
formed using ion implantation. Furthermore, a silicon oxynitride
film 422 and a silicon oxide film 423, which serve as an inter
layer dielectric, are formed by reduced-pressure CVD so as to cover
the entire surface, thereby completing nonvolatile memory
cells.
[0161] According to the seventh embodiment, even where the inter
electrode insulating film has a reducing property due to hydrogen,
the reliability of the tunnel insulating film can be enhanced while
suppressing insulation property deterioration due to reduction
caused by the inter electrode insulating film.
(14) EIGHTH EMBODIMENT
[0162] A method of manufacturing a semiconductor device according
to an eighth embodiment of the present invention will be described.
The eighth embodiment corresponds to an example of applying the
present invention to a nonvolatile memory. It is assumed that:
FIGS. 38(a), 39(a), 40(a), 41(a), 42(a) and 43(a) are
cross-sectional views in the word-line (channel-width) direction;
and FIGS. 38(b), 39(b), 40(b), 41(b), 42(b) and 43(b) correspond to
cross-sectional views in the bit-line direction
(channel-length).
[0163] First, as illustrated in FIGS. 38(a) and 38(b), a mask
material 502 for isolation process is deposited on the surface of a
semiconductor substrate 501 doped with a desired impurity, by means
of CVD. By means of RIE using a resist mask (not shown), the mask
material 502 is etched, and the exposed regions of the
semiconductor substrate 501 are etched, forming isolation trenches
503 with a depth of 100 nm. It is assumed that the width of the
isolation trenches 503 and the width of the element-forming regions
are both approximately 40 nm.
[0164] Next, as illustrated in FIGS. 39(a) and 39(b), a silicon
oxide film 504 for isolation is deposited on the entire surface to
completely fill the isolation trenches 503. Subsequently, the
surface parts of the silicon oxide film 504 are removed by CMP to
planarize the surface. Consequently, the surface of the mask
material 502 is exposed.
[0165] Next, as illustrated in FIGS. 40(a) and 40(b), the exposed
mask material 502 is selectively removed by etching using, e.g., a
chemical solution. Furthermore, the exposed surface of the silicon
oxide film 504 is removed by etching using a diluted hydrofluoric
acid solution to be at the same level as the semiconductor
substrate 501.
[0166] Next, as illustrated in FIGS. 41(a) and 41(b), a tunnel
oxide film 505 with a thickness of 3 nm is formed by ALD (Atomic
Layer Deposition). A silicon nitride film 506 with a thickness of 5
nm, which serves as a charge storage layer, is deposited by CVD,
and an alumina film 507 with a thickness of 30 nm, which serves as
a charge block layer, is deposited by ALD (Atomic Layer
Deposition). Furthermore, a conductive layer 508 with a thickness
of 100 nm, the conductive layer 508 having a two-layer structure
consisting of a polysilicon layer and a tungsten silicide layer,
and becoming control gate electrodes, is deposited by CVD.
[0167] Next, as illustrated in FIGS. 42(a) and 42(b), a silicon
nitride film 509, which serves as a mask material for RIE, is
deposited by CVD. By means of RIE using a resist mask (not shown)
having a pattern perpendicular to that of the isolation trenches
503, the mask material 509, the conductive layer 508 as control
gate electrodes, the alumina film 507 as a charge block layer, and
the silicon nitride film 506 as a charge storage layer are
sequentially etched to form control gate electrodes. It is assumed
that the width of the silicon nitride film 506 and the distance
between adjacent parts of the silicon nitride film 506 are both
approximately 40 nm. The tunnel oxide film 505 is an example of a
first film to be processed in the present invention, and a film
including the silicon nitride film 506, the alumina film 507, and
the conductive layer 508 is an example of a second film to be
processed in the present invention.
[0168] Here, the silicon nitride film 506 as a charge storage layer
may be formed in the shape in which the width increases toward its
lower part, i.e., what is called a skirt shape.
[0169] Next, as illustrated in FIGS. 43(a) and (b), using
anisotropic oxidation, oxidizing ions are generated from a gas
mixture by microwaves, radio-frequency waves or electron cyclotron
resonance, and a radio-frequency wave voltage of, for example, 10
to 100 V is applied to the semiconductor substrate. Consequently,
oxidizing ions are accelerated toward the semiconductor substrate
501 and substantially perpendicularly enter the semiconductor
substrate 501, whereby oxidation of the sidewalls of the silicon
nitride film 506 as a charge storage layer and the conductive layer
508 as control gate electrodes is suppressed, and the exposed
tunnel insulating film 505 is selectively oxidized to subject the
tunnel insulating film 505 to oxidation reforming, forming a
reformed region 512. Here, although FIG. 43 illustrates the case
where the exposed tunnel insulating film 505 is entirely changed
into the reform region 512, only the surface parts of the tunnel
insulating film 505 may be reformed, by performing the anisotropic
oxidation shorter or at lower temperature, or changing the material
of the tunnel insulating film to such a material that is not easily
oxidized. Alternatively, an oxide layer may be formed on the
surface parts of the silicon substrate 501 in the exposed regions
of the tunnel insulating film.
[0170] Consequently, it is possible to suppress oxidation of the
sidewall parts of the conductive layer 508 as control gate
electrodes to avoid a decrease in the width of the control gate
electrodes, and furthermore, to prevent the shapes of parts of an
impurity diffusion layer from varying due to the oxide layer formed
on the sidewall parts of the control gate electrodes. In addition,
the exposed parts of the tunnel insulating film 505 are reformed by
the oxidizing ions, which can improve the reliability of the tunnel
insulating film 505.
[0171] Where the silicon nitride film 506 as a charge storage layer
have a skirt shape, the bottom part of the film is selectively
oxidized to have a large thickness, enabling suppression of
erroneous cell operation and variation in cell operation
characteristics.
[0172] In the subsequent process, a gate sidewall oxide film 510
with a thickness of 10 nm is formed by CVD. An impurity diffusion
layer 513 is formed by performing ion implantation and thermal
annealing. An inter later insulating film 511 is formed using,
e.g., CVD, and furthermore, an interconnect layer, etc., (not
shown) is formed to complete nonvolatile memory cells.
(15) NINTH EMBODIMENT
[0173] A method of manufacturing a semiconductor device according
to a ninth embodiment of the present invention will be described.
The ninth embodiment corresponds to an example of applying the
present invention to an apparatus in which an SOI-structure region
is formed on a part of the semiconductor substrate to form a
peripheral circuit region on the semiconductor substrate, and a
memory cell region on the SOI-structure region of the same
semiconductor substrate.
[0174] As illustrated in FIG. 44, in order to provide a level
difference between a peripheral circuit region 602 and a memory
cell region 603, a mask material (not shown), which is formed of,
e.g., a silicon nitride film, is deposited on a semiconductor
substrate 601 by CVD.
[0175] By means of RIE using a resist mask (not shown), the mask
material is etched to be partially exposed. Using this mask
material, the exposed region of the semiconductor substrate 601 is
removed by etching to form a peripheral circuit region 602, which
is a planar part where a peripheral circuit is to be formed, and a
memory cell region 603, which is a planar part where memory cells
are to be formed, there being a level difference of 50 nm between
the peripheral circuit region 602 and the memory cell region 603.
As illustrated in FIG. 44, the level of the upper surface of the
peripheral circuit region 602 is set to be higher than the level of
the upper surface of the memory cell region 603. The planar part
where a peripheral circuit is to be formed is an example of a first
planar part of the present invention, and the planar part where
memory cells are to be formed is an example of a second planar part
of the present invention.
[0176] Using anisotropic oxidation, oxidizing ions are generated by
microwaves, radio-frequency waves or electron cyclotron resonance,
and a radio-frequency wave voltage of, for example, 10 to 100 V is
applied to the semiconductor substrate 601. Consequently, the
oxidizing ions are accelerated toward the semiconductor substrate
601 and substantially perpendicularly enter the semiconductor
substrate 601. In FIG. 45, while suppressing oxidation of a
sidewall part 606 of the stepped structure, the peripheral circuit
region 602 and the memory cell region 603, which are planar parts,
are selectively oxidized to form silicon oxide films 604 and 605
each having a thickness of 10 nm in the peripheral circuit region
602 and the memory cell region 603, respectively. The sidewall part
606 is an example of a step part according to the present
invention, which is located at the boundary between the peripheral
circuit region 602 and the memory cell region 603.
[0177] Although the silicon oxide films 604 and 605 are formed
using anisotropic oxidation here, silicon nitride films may be
formed similarly in the peripheral circuit region 602 and the
memory cell region 603 using anisotropic nitridation.
[0178] Subsequently, chemical etching using a diluted hydrofluoric
acid solution or a hot phosphoric acid solution is performed to the
extent that a sidewall oxide film formed on the sidewall part 606
of the stepped structure is removed. Furthermore, as illustrated in
FIG. 46, an amorphous silicon film 607 having a thickness of 100 nm
is deposited on the entire surface using reduced-pressure CVD.
Annealing is performed to single-crystallize the amorphous silicon
film 607. The amorphous layer 607 is an example of a semiconductor
layer according to the present invention.
[0179] As illustrated in FIG. 47, the amorphous silicon film 607 is
subjected to CMP to remove the amorphous silicon film 607 on the
peripheral circuit region 602, and to remove a part of the
amorphous silicon film 607 on the memory cell region 603, thereby
planarizing the upper surface of the amorphous silicon film 607,
and making the upper surface of the silicon oxide film 604 on the
peripheral circuit region 602 be exposed. Consequently, the height
of the upper surface of the amorphous silicon film 607 on the
memory cell region 603 is lowered to the height of the upper
surface of the silicon oxide film 604 on the peripheral circuit
region 602. This makes the height of the upper surface of the
amorphous silicon film 607 on the memory cell region 603 be
substantially equal to the height of the upper surface of the
silicon oxide film 604 on the peripheral circuit region 602.
Through the subsequent process, memory cells are formed in the
memory cell region 602 and peripheral circuits are formed in the
peripheral circuit region 603 to complete a semiconductor
device.
[0180] According to the ninth embodiment, a silicon oxide film
formed on the sidewall part 606, which provides a level difference,
is removed, and furthermore, oxidation or nitridation of the
sidewall part 606 is suppressed when performing epitaxial growth on
the semiconductor substrate 601, enabling suppressing displacement
of the position of the step part due to forming and removing the
silicon oxide film or the silicon nitride film on this part.
Consequently, there is no fear of hindrance for forming circuits
using the position of the sidewall part 606 as a reference.
[0181] All the above embodiments are mere examples, and various
modifications can be made within the technical scope of the present
invention. For example, anisotropic oxidation in the respective
embodiments may be substituted with anisotropic nitridation, or
anisotropic nitridation may be performed as a substitute for
anisotropic oxidation.
[0182] Also, aspects of a method of manufacturing a semiconductor
device according to the present invention include methods described
below.
[0183] The aspects of the present invention include, for example, a
method of manufacturing a semiconductor device comprising: forming
a first film, which becomes a dummy gate film, on a semiconductor
substrate; removing a predetermined region of the first film by
etching to form a dummy gate film and make a surface of the
semiconductor substrate be partially exposed; forming a first
insulating film so as to cover the dummy gate film; performing
etching of the first insulating film to form a sidewall insulating
film, which includes the first insulating film, on a side surface
of the dummy gate film; forming a second insulating film so as to
cover the dummy gate film and the sidewall insulating film;
planarizing a surface part of the second insulating film to make an
upper part of the dummy gate film be exposed; removing the dummy
gate film to form a slit part including sidewall parts including
side surfaces of the sidewall insulating film and a bottom part
including a surface of the semiconductor substrate; forming a third
insulating film, which becomes a part of a gate insulation film, at
least on a bottom surface of the slit part; applying a
predetermined voltage to the semiconductor substrate to supply
oxidizing ions contained in plasma generated by any of a microwave,
a radio-frequency wave and electron cyclotron resonance or
nitriding ions contained in the plasma to the sidewall parts of the
slit part and the bottom part of the slit part, thereby performing
anisotropic oxidation or anisotropic nitridation of the sidewall
parts of the slit part and the bottom part of the slit part; and
depositing a conductive material as a material for a gate electrode
so as to fill the slit part.
[0184] Also, the aspects of the present invention include, for
example, a method of manufacturing a semiconductor device
comprising: forming a first film, which becomes a dummy gate film,
on a semiconductor substrate; removing the first film and a part of
the semiconductor substrate, the part having a predetermined depth,
in a predetermined region by etching to form a dummy gate film and
forming a plurality of isolation trenches along a first direction;
filling the plurality of isolation trenches with a first insulating
film; planarizing a surface part of the first insulating film to
make an upper surface of the dummy gate film be exposed; removing
the dummy gate film to form a slit part including sidewall parts
including side surfaces of the first insulating film and a bottom
part including a surface of the semiconductor substrate; forming a
second insulating film, which becomes a part of a tunnel insulating
film, at least on a bottom surface of the slit part; applying a
predetermined voltage to the semiconductor substrate to supply
oxidizing ions contained in plasma generated by any of a microwave,
a radio-frequency wave and electron cyclotron resonance or
nitriding ions contained in the plasma to the sidewall parts of the
slit part and the bottom part of the slit part, thereby performing
anisotropic oxidation or anisotropic nitridation of the sidewall
parts of the slit part and the bottom part of the slit part,
thereby forming a tunnel insulating film; forming a floating gate
electrode on the tunnel insulating film; and sequentially forming
an inter electrode insulating film and a control gate electrode on
the floating gate electrode and the first insulating film.
[0185] As described above, the embodiments of a method of
manufacturing a semiconductor device according to the present
invention enable problems arising when performing isotropic
oxidation or nitridation of the sidewall parts and bottom parts of
the isolation trenches and/or the gate electrodes to be solved.
[0186] Although specific examples of aspects of the present
invention have been described by the first to ninth embodiments,
the present invention is not limited to these embodiments.
* * * * *