U.S. patent application number 15/186628 was filed with the patent office on 2016-10-06 for high mobility stabile metal oxide tft.
The applicant listed for this patent is Fatt Foong, Juergen Musolf, Chan-Long Shieh, Tian Xiao, Gang Yu. Invention is credited to Fatt Foong, Juergen Musolf, Chan-Long Shieh, Tian Xiao, Gang Yu.
Application Number | 20160293769 15/186628 |
Document ID | / |
Family ID | 49777162 |
Filed Date | 2016-10-06 |
United States Patent
Application |
20160293769 |
Kind Code |
A1 |
Shieh; Chan-Long ; et
al. |
October 6, 2016 |
HIGH MOBILITY STABILE METAL OXIDE TFT
Abstract
A method of fabricating a stable, high mobility metal oxide thin
film transistor includes the steps of providing a substrate,
positioning a gate on the substrate, and depositing a gate
dielectric layer on the gate and portions of the substrate not
covered by the gate. A multiple film active layer including a metal
oxide semiconductor film and a metal oxide passivation film is
deposited on the gate dielectric with the passivation film
positioned in overlying relationship to the semiconductor film. An
etch-stop layer is positioned on a surface of the passivation film
and defines a channel area in the active layer. A portion of the
multiple film active layer on opposite sides of the etch-stop layer
is modified to form an ohmic contact and metal source/drain
contacts are positioned on the modified portion of the multiple
film active layer.
Inventors: |
Shieh; Chan-Long; (Paradise
Valley, AZ) ; Yu; Gang; (Santa Barbara, CA) ;
Foong; Fatt; (Goleta, CA) ; Xiao; Tian;
(Goleta, CA) ; Musolf; Juergen; (Santa Barbara,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shieh; Chan-Long
Yu; Gang
Foong; Fatt
Xiao; Tian
Musolf; Juergen |
Paradise Valley
Santa Barbara
Goleta
Goleta
Santa Barbara |
AZ
CA
CA
CA
CA |
US
US
US
US
US |
|
|
Family ID: |
49777162 |
Appl. No.: |
15/186628 |
Filed: |
June 20, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13536641 |
Jun 28, 2012 |
9379247 |
|
|
15186628 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 21/4763 20130101;
H01L 29/0649 20130101; H01L 21/467 20130101; H01L 29/78696
20130101; H01L 29/41733 20130101; H01L 29/7869 20130101; H01L
29/66969 20130101; H01L 23/535 20130101 |
International
Class: |
H01L 29/786 20060101
H01L029/786; H01L 23/535 20060101 H01L023/535; H01L 21/467 20060101
H01L021/467; H01L 29/66 20060101 H01L029/66; H01L 21/4763 20060101
H01L021/4763; H01L 29/417 20060101 H01L029/417; H01L 29/06 20060101
H01L029/06 |
Claims
1. A metal oxide thin film transistor comprising: a substrate; a
gate positioned on an upper surface of the substrate; a gate
dielectric layer positioned on the gate and portions of the
substrate not covered by the gate; a multiple film active layer
positioned on the gate dielectric layer; an etch-stop layer
covering a portion of the multiple film active layer and defining a
channel area in the active layer; metal source/drain contacts
positioned on the active layer on opposite sides of the etch-stop
layer; and the multiple films of the active layer including a metal
oxide semiconductor film and a metal oxide passivation film, the
metal oxide passivation film being positioned between the metal
oxide semiconductor film and the etch-stop layer and having a major
upper surface contacting the etch-stop layer in the channel area
and the metal source/drain contact areas on each side of the
channel area, and the metal oxide passivation film includes
aluminum.
2. A metal oxide thin film transistor as claimed in claim 1 wherein
the metal oxide semiconductor film of the active layer has a
mobility >20 cm.sup.2/Vs.
3. A metal oxide thin film transistor as claimed in claim 2 wherein
the metal oxide semiconductor film of the active layer includes
indium.
4. A metal oxide thin film transistor as claimed in claim 1 wherein
the metal oxide passivation film of the active layer includes a
metal that can be selectively modified by exposure to a strong base
material.
5. (canceled)
6. A metal oxide thin film transistor as claimed in claim 1 wherein
the metal oxide semiconductor film of the active layer includes one
of In.sub.2O.sub.3 and InZnO and the passivation film of the active
layer includes one of InAlZnO and AlZnO.
7. A metal oxide thin film transistor as claimed in claim 1 wherein
the etch-stop layer includes an organic passivation material.
8. A metal oxide thin film transistor as claimed in claim 1 wherein
the multiple film active layer includes a contact layer between the
metal oxide passivation film and the etch-stop layer and the metal
source/drain contacts.
9. A metal oxide thin film transistor as claimed in claim 8 wherein
the etch-stop layer includes an oxygen donating material.
10. A metal oxide thin film transistor as claimed in claim 1
wherein the multiple films of the active layer further include a
thin film of oxygen bonded metal adjacent the gate dielectric
layer.
11. A metal oxide thin film transistor as claimed in claim 10
wherein the thin film of oxygen bonded metal is less than 5
molecular layers thick.
12. A metal oxide thin film transistor comprising: a substrate; a
gate positioned on an upper surface of the substrate; a gate
dielectric layer positioned on the gate and portions of the
substrate not covered by the gate; a multiple film active layer
positioned on the gate dielectric layer; an etch-stop layer
covering a portion of the multiple film active layer and defining a
channel area in the active layer, the etch stop layer including an
oxygen donating material; metal source/drain contacts positioned on
the active layer on opposite sides of the etch-stop layer; and the
multiple films of the active layer including a metal oxide
semiconductor film, a metal oxide passivation film, and a contact
film, the metal oxide passivation film being positioned between the
metal oxide semiconductor film and the contact film and the contact
film being positioned between the metal oxide passivation film and
the etch-stop layer.
13. A metal oxide thin film transistor comprising: a substrate; a
gate positioned on an upper surface of the substrate; a gate
dielectric layer positioned on the gate and portions of the
substrate not covered by the gate; a multiple film active layer
positioned on the gate dielectric layer; an etch-stop layer
covering a portion of the multiple film active layer and defining a
channel area in the active layer, the etch stop layer including an
oxygen donating material; metal source/drain contacts positioned on
the active layer on opposite sides of the etch-stop layer; and the
multiple films of the active layer including a thin film of oxygen
bonded metal adjacent the gate dielectric layer, the oxygen bonded
metal having a thickness less than approximately 5 molecular
layers.
14. A metal oxide thin film transistor comprising: a substrate; a
gate positioned on an upper surface of the substrate; a gate
dielectric layer positioned on the gate and portions of the
substrate not covered by the gate; a multiple film active layer
positioned on the gate dielectric layer; an etch-stop layer
covering a portion of the multiple film active layer and defining a
channel area in the active layer; metal source/drain contacts
positioned on the active layer on opposite sides of the etch-stop
layer; and the multiple films of the active layer including a metal
oxide semiconductor film and a metal oxide passivation film, the
metal oxide passivation film being positioned between the metal
oxide semiconductor film and the etch-stop layer, and the metal
source/drain contacts being positioned on the metal oxide
semiconductor film.
15-34. (canceled)
35. In a metal oxide thin film transistor including a substrate, a
gate positioned on the substrate, a gate dielectric layer
positioned on the gate and portions of the substrate not covered by
the gate, an active layer positioned on the gate dielectric layer,
and an etch-stop layer positioned on the active layer so as to
define a channel area in the active layer, a method of fabricating
a stable, high mobility active layer comprising the steps of:
forming the active layer with a plurality of films including a
metal oxide semiconductor film and a metal oxide passivation film,
the metal oxide passivation film having a major upper surface and
including aluminum, and the metal oxide passivation film being
positioned between the metal oxide semiconductor film and the
etch-stop layer; modifying a portion of the upper major surface of
the metal oxide passivation film including treating the aluminum
with a base material to remove the aluminum from the portion of the
upper major surface of the metal oxide passivation film to increase
the conductivity, the base material being other than gas-phase
ammonia; and removing a portion of the metal oxide passivation film
on opposite sides of the etch-stop layer to expose a surface of the
metal oxide semiconductor film and positioning the metal
source/drain contacts on the exposed surface of the metal oxide
semiconductor film.
36. A method as claimed in claim 35 wherein the step of forming the
active layer with a plurality of films further includes a step of
forming a contact layer of metal between the metal oxide
passivation film and the etch-stop layer and the metal source/drain
contacts, and a step of forming the etch-stop layer of oxygen
donating material.
37. A method as claimed in claim 35 wherein the step of forming the
active layer with a plurality of films further includes a step of
forming a thin film of oxygen bonding metal adjacent the gate
dielectric layer.
38. A method as claimed in claim 37 wherein the step of forming the
thin film of oxygen bonding metal includes forming the film of
oxygen bonding metal less than approximately 5 molecular layers
thick.
39. A method as claimed in claim 35 wherein the step of forming the
thin film of oxygen bonding metal includes forming the film of
oxygen bonding metal by sputter deposition.
40. A method as claimed in claim 35 wherein the step of forming the
thin film of oxygen bonding metal includes a coating process with a
solution comprising organo-metallic molecules comprising the
corresponding metal, and followed with a reduction process in a
chamber with inert gas or in a vacuum.
41. The method as claimed in claim 35 wherein the thin film of
oxygen bonding metal comprise Al, Si, B, Ta, Mg, Ti or their
combination.
42. The method as claimed in claim 35 wherein the thin film of the
oxygen bonding metal has a metal-oxygen bonding strength large than
100 cal/mol.
43. The method as claimed in claim 35 wherein the step of forming
the metal oxide semiconductor film and the metal oxide passivation
film in the active layer is by sputter deposition.
44. A metal oxide thin film transistor as claimed in claim 1
wherein the substrate is glass, plastic, or stainless steel
sheet.
45. A metal oxide thin film transistor as claimed in claim 1
wherein the gate dielectric layer comprises SiO2, SiN, Al2O3, HfO,
or their combination in multiple layer stack.
46. A metal oxide thin film transistor as claimed in claim 1
wherein the etch-stop layer includes oxygen.
47. A metal oxide thin film transistor as claimed in claim 1
wherein the etch-stop layer comprises organic material.
48. A metal oxide thin film transistor as claimed in claim 5D
wherein the organic material in the etch-stop layer is
photo-patternable.
49. The metal oxide thin film transistor as claimed in claim 10
wherein the thin film of oxygen bonded metal comprise Al, Si, B,
Ta, Mg, Ti or their combination.
50. The metal oxide thin film transistor as claimed in claim 10
wherein the thin film of oxygen bonded metal has metal-oxygen
bonding strength large than 100 cal/mol.
Description
FIELD OF THE INVENTION
[0001] This invention generally relates to operationally stable,
high mobility thin film transistors (TFTs).
BACKGROUND OF THE INVENTION
[0002] The metal oxide thin film transistor (MOTFT) has shown great
promise for large area electronic applications such as displays and
digital image sensor arrays. The major advantage of the MOTFT is
the ability to achieve high mobility in the
amorphous/nanocrystalline phase. The amorphous/nanocrystalline
phase insures short range uniformity similar to that observed in
a-Si TFT. However, the key challenge for MOTFTs is the operation
stability at high temperature or under high biasing fields. High
mobility metal oxide such as In.sub.2O.sub.3 and InZnO tends to be
unstable under negative field bias at high temperatures. To improve
the negative bias stability, more stable elements such as Ga have
been added into the metal oxide (e.g. InGaZnO) which tends to
sacrifice mobility considerably. Thus, in the prior art the
tradeoff is between operational stability and mobility.
[0003] It would be highly advantageous, therefore, to remedy the
foregoing and other deficiencies inherent in the prior art.
[0004] Accordingly, it is an object of the present invention to
provide a new and improved MOTFT with improved operational
stability and high mobility.
[0005] It is another object of the present invention to provide new
and improved methods of fabricating MOTFTs with improved
operational stability and high mobility.
[0006] It is another object of the present invention to provide new
and improved methods and apparatus for reducing the V.sub.th shift
under negative and positive bias temperature stress in a MOTFT.
SUMMARY OF THE INVENTION
[0007] The desired objects of the instant invention are achieved in
accordance with an embodiment thereof wherein a metal oxide thin
film transistor includes a substrate, a gate positioned on an upper
surface of the substrate, and a gate dielectric layer positioned on
the gate and portions of the substrate not covered by the gate. A
multiple film active layer is positioned on the gate dielectric
layer. An etch-stop layer covers a portion of the multiple film
active layer and defines a channel area in the active layer. Metal
source/drain contacts are positioned on the active layer on
opposite sides of the etch-stop layer. The multiple films of the
active layer include a metal oxide semiconductor film and a metal
oxide passivation film. The metal oxide passivation film is
positioned between the metal oxide semiconductor film and the
etch-stop layer. A portion of the multiple film active layer on
opposite sides of the etch-stop layer is modified to increase the
conductivity and provide a good ohmic contact and the metal
source/drain contacts are positioned on the modified portion of the
multiple film active layer
[0008] The desired objects of the instant invention are achieved in
accordance with a specific embodiment thereof wherein the metal
oxide thin film transistor includes a multiple film active layer
with a contact layer between the metal oxide passivation film and
the etch-stop layer and the etch-stop layer includes an oxygen
donating material.
[0009] The desired objects of the instant invention are achieved in
accordance with another specific embodiment thereof wherein the
metal oxide thin film transistor includes a thin metal film
positioned between the metal oxide semiconductor film and the gate
dielectric layer. In this embodiment the thin metal film includes
an oxygen bonding metal and has a thickness less than approximately
5 molecular layers thick.
[0010] Briefly, the desired objects of the instant invention are
further achieved in accordance with a method of fabricating a
stable, high mobility metal oxide thin film transistor. The method
includes the steps of providing a substrate, positioning a gate on
the substrate, and depositing a gate dielectric layer on the gate
and portions of the substrate not covered by the gate. A multiple
film active layer including a metal oxide semiconductor film and a
metal oxide passivation film is deposited on the gate dielectric
with the passivation film positioned in overlying relationship to
the semiconductor film. An etch-stop layer is positioned on a
surface of the passivation film and defines a channel area in the
active layer. A portion of the multiple film active layer on
opposite sides of the etch-stop layer is modified to form an ohmic
contact and metal source/drain contacts are positioned on the
modified portion of the multiple film active layer.
[0011] The desired objects of the instant invention are also
achieved in accordance with a method of fabricating a stable, high
mobility metal oxide thin film transistor wherein the metal oxide
thin film transistor includes a substrate, a gate positioned on the
substrate, a gate dielectric layer positioned on the gate and
portions of the substrate not covered by the gate, an active layer
positioned on the gate dielectric layer, an etch-stop layer
positioned on the active layer so as to define a channel area in
the active layer, and metal source/drain contacts positioned on the
active layer on opposite sides of the etch-stop layer and the
method of fabricating a stable, high mobility active layer includes
the steps of forming the active layer with a plurality of films
including a metal oxide semiconductor film and a metal oxide
passivation film and positioning the metal oxide passivation film
between the metal oxide semiconductor film and the etch-stop
layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing and further and more specific objects and
advantages of the instant invention will become readily apparent to
those skilled in the art from the following detailed description of
a preferred embodiment thereof taken in conjunction with the
drawings, in which:
[0013] FIG. 1 is a simplified layer diagram of a typical MOTFT with
a passivation layer and ohmic source-drain contacts;
[0014] FIG. 2 is a graph illustrating V.sub.th shift in the MOTFT
of FIG. 1 under negative and positive bias fields;
[0015] FIG. 3 is a simplified layer diagram of an example of a
MOTFT with improved operational stability and high mobility, in
accordance with the present invention;
[0016] FIG. 4 is a graph illustrating V.sub.th stability in the
MOTFT of FIG. 3 under negative bias fields;
[0017] FIG. 5 is a simplified layer diagram of another example of a
MOTFT with improved operational stability and high mobility, in
accordance with the present invention;
[0018] FIG. 6 is a simplified layer diagram of another example of a
MOTFT with improved operational stability and high mobility, in
accordance with the present invention; and
[0019] FIG. 7 is a simplified layer diagram of an example of
another MOTFT with improved operational stability and high
mobility, in accordance with the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0020] Referring specifically to FIG. 1, a simplified layer diagram
of a typical MOTFT 10 with a passivation layer and ohmic
source-drain contacts is illustrated. In this specific example,
MOTFT 10 is a bottom gate and top source/drain metal oxide TFT. It
will be understood that the present invention can apply to any of
the numerous MOTFTs and MOTFT 10 is simply shown for illustrative
purposes only. MOTFT 10 includes a substrate 12 which is typically
made of glass or plastic sheet with a proper passivation coating.
For certain applications, an additional passivation layer and/or
buffer layer may be added on the top surface of substrate 12 and
for purposes of this disclosure all of the examples (e.g.
passivation layer, buffer layer, etc.) will be included in the term
"substrate".
[0021] MOTFT 10 includes substrate 12 with gate metal 14 patterned
thereon. A gate dielectric layer 16 is deposited over gate metal 14
and a metal oxide semiconductor active layer 18 is deposited over
dielectric layer 16 so as to insulate active layer 18 from gate
metal 14. A passivation layer 20 is patterned on active layer 18
and source/drain contacts 22 are formed on opposite sides of
passivation layer 20 on exposed upper surfaces of active layer 18.
The space between the source and drain defines the conduction
channel, designated 24, for MOTFT 10. While the bottom gate and top
source/drain metal oxide TFT is primarily of interest in the
present invention, it is believed that any of the various possible
MOTFT configurations could be adapted to the disclosed method
including for example a bottom gate, bottom source/drain type of
device, a top gate, top source/drain type of device, etc.
[0022] In MOTFT 10 the top surface of the metal oxide conduction
channel 18 is protected by etch-stop layer 20. In U.S. Pat. No.
7,812,346, (incorporated herein by reference) a series of organic
and inorganic dielectric films are disclosed for use as such
etch-stop layers. The organic etch-stop layers are deposited by
solution coating or dispensing and can be patterned easily for
example by using a photolithographic patterning process without
damaging the underlying film. A problem with organic dielectric
films is that they are not as good as inorganic dielectric films in
terms of protection against water (humidity) penetration from
ambient environment. Water absorption at the surface and
penetration through etch-stop layer 20 have been identified to be
the source of threshold voltage shift under negative field bias.
Note that source/drain contacts 22 are formed of thick metal and
provide very good protection against the penetration of moisture.
Referring additionally to FIG. 2, a typical V.sub.th curve,
designated 25, for MOTFET 10 is illustrated. Curve 26 illustrates a
shift in the V.sub.th curve under for example a negative 20 volt
bias field at 60.degree. C. for some period of time, such as an
hour.
[0023] Inorganic etch-stop layers or films are harder to provide in
terms of deposition and patterning, i.e. they must be deposited at
relatively high temperatures and because of the deposition
techniques that must be used it is difficult to deposit thick
enough layers. Both the deposition and patterning of inorganic
layers can cause substantial damage to the underlying metal oxide
film thereby substantially reducing the mobility. To summarize, the
underlying film surface (i.e. metal oxide semiconductor active
layer 18) has to be very stable against water and other processing
damage. Such a stable film usually has a lower mobility. Thus, in
the prior art there is a tradeoff between mobility and negative
bias stress stability.
[0024] In order to achieve a high mobility MOTFET with good
negative bias stress stability at high operation temperatures, a
two film channel or active layer is proposed in this invention. In
the two film structure, the bottom conduction film is optimized for
high mobility and may not be so stable against environmental
attack. Examples of such a conduction layer are In.sub.2O.sub.3 and
InZnO. The top or passivation film is a more stable metal oxide
film with lower mobility and lower carrier concentration, such as
InAlZnO, AlZnO, etc. In a preferred method of fabrication, the two
films of the structure can be deposited in a single sputter machine
without breaking the vacuum (i.e. deposited in situ). Operation
consistency is thus warranted, as well as simplicity. One challenge
to the two film structure is to make a good ohmic contact between
the source/drain metal and the top passivation film. To this end
three examples are illustrated and explained below.
[0025] Referring specifically to FIG. 3, a first example is
illustrated of a MOTFT 30 with improved operational stability and
high mobility, in accordance with the present invention. MOTFET 30
includes a substrate 31 with a bottom gate 32 patterned in the
upper surface. A gate dielectric layer 33 is deposited over gate 32
and the upper surface of substrate 31. An active layer 34, which in
this example includes an upper passivation film 36 and an
underlying conduction film 35, is deposited on the upper surface of
gate dielectric layer 33. An etch-stop layer 37 is provided on the
upper surface of active layer 34 and defines the channel area 38 in
active layer 34. Source/drain metal contacts 39 are deposited on
either side of etch-stop layer 37 to complete MOTFT 30.
[0026] In the preferred embodiment underlying conduction film 35
includes a high mobility semiconductor metal oxide including high
concentrations of indium, such as In.sub.2O.sub.3, InZnO, and the
like. Underlying conduction film 35 may be for example
approximately 200 nm thick. Also, in this specific example upper
passivation film 36 is a much more stable and lower mobility metal
oxide material. Upper passivation film 35 is very thin and may be
for example less than approximately 50 nm thick. Further, upper
passivation film 36 is a material that can be selectively modified
(at least the upper surface) by exposure to a strong base such as
KOH, TMAH (tri methyl ammonia hydroxide) etc.
[0027] As a typical example of the two film active layer, any
passivation film with a high aluminum content (e.g. InAlZnO) will
be attacked selectively by the strong base. The attack by the
strong base will remove the aluminum and thereby increase the
conductivity and carrier concentration which will enable a good
ohmic contact to the modified passivation film. It will be noted
that etch-stop layer 37 is generally deposited in a blanket form
and patterned to leave the portion illustrated. Also, the material
used during patterning of etch-stop layer 37 (generally a strong
base) may be sufficient to modify passivation film 36. Since
channel area 38 is protected by etch-stop layer 37, passivation
film 36 remains unmodified by the strong base and provides
protection against environmental attack.
[0028] The major lateral conduction between source and drain is
carried by the high mobility underlying conduction film 35. The
modified upper passivation layer (in the source/drain contact
areas) enables a good ohmic contact and the vertical resistance
from the contact metal 39 to underlyinh conduction film 35 is very
small because passivation film 36 is very thin and the ohmic
contact is good at the operating current density (typically
<10.sup.3 Ohms). Thus, a very high mobility (>20 cm.sup.2/Vs)
with a very good negative bias stability at high temperatures can
be produced. A metal oxide transistor fabricated in accordance with
the above method showed mobility more than 35 cm.sup.2/Vs and a
negative bias stability illustrated in FIG. 4. In FIG. 4 it can be
seen that the V.sub.th curve remained stationary with changing bias
field between 0 mv/cm and 60 mv/cm and an operating temperature of
60.degree. C. for a period in excess of an hour.
[0029] Referring specifically to FIG. 5, a second example is
illustrated of a MOTFT 50 with improved operational stability and
high mobility, in accordance with the present invention. MOTFET 50
includes a substrate 51 with a bottom gate 52 patterned in the
upper surface. A gate dielectric layer 53 is deposited over gate 52
and the upper surface of substrate 51. An active layer 54, which in
this example includes a underlying conduction film 55 and an upper
passivation film 56, is deposited on the upper surface of gate
dielectric layer 53. An etch-stop layer 57 is provided on the upper
surface of active layer 54 and defines the channel area 58 in
active layer 54. Source/drain metal contacts 59 are deposited on
either side of etch-stop layer 57 to complete MOTFT 50.
[0030] In the preferred embodiment underlying conduction film 55
includes a high mobility semiconductor metal oxide including high
concentrations of indium, such as In.sub.2O.sub.3, InZnO, and the
like. Underlying conduction film 55 may be for example
approximately 200 nm thick. Also, in this specific example upper
passivation film 56 is a much more stable and lower mobility metal
oxide material. Upper passivation film 55 is very thin and may be
for example less than approximately 50 nm thick. Further, upper
passivation film 56 is a material that can be selectively modified
(at least the upper surface) by exposure to a strong base such as
KOH, TMAH (tri methyl ammonia hydroxide) etc. As a typical example
the passivation film can be Al.sub.2O.sub.3 which will be attacked
selectively by the strong base and, in this example, passivation
layer 56 is etched away leaving conductive film 55 exposed in the
source/drain contact areas. Thus a good ohmic contact can be made
to conductive film 55 and passivation film 56 remains intact
between etch-stop layer 57 and conductive film 55 so that
conductive film is not attacked by ambient moisture.
[0031] Referring specifically to FIG. 6, a third example is
illustrated of a MOTFT 60 with improved operational stability and
high mobility, in accordance with the present invention. MOTFET 60
includes a substrate 61 with a bottom gate 62 patterned in the
upper surface. A gate dielectric layer 63 is deposited over gate 62
and the upper surface of substrate 61. An active layer 64, which in
this example includes a underlying conduction film 65, a middle
passivation film 66, and an upper contact film 67 is deposited on
the upper surface of gate dielectric layer 63. An etch-stop layer
68 is provided on the upper surface of active layer 64 and defines
the channel area in active layer 64. Source/drain metal contacts 69
are deposited on either side of etch-stop layer 68 to complete
MOTFT 60.
[0032] In the preferred embodiment underlying conduction film 65
includes a high mobility semiconductor metal oxide including high
concentrations of indium, such as In.sub.2O.sub.3, InZnO, and the
like. Underlying conduction film 65 may be for example
approximately 200 nm thick. Also, in this specific example middle
passivation film 66 is a much more stable and lower mobility metal
oxide material. Middle passivation film 65 may be for example
ZnO.sub.2 or the like. Upper contact film 67 is very thin and may
be for example a few monolayers (1-5 monolayers) of metal or metal
oxide to provide a good ohmic contact.
[0033] In this example, the etch-stop material in layer 68 is an
oxygen donating material which can render the thin contact film 67
nonconducting, i.e. the metal is modified to a metal oxide. In
contact areas where the source/drain metal 69 covers contact film
67 there is no oxygen donating etch-stop and the top contact layer
67 remains conductive to facilitate ohmic contact. During an
annealing process after processing etch-stop layer 68 or after
processing source/drain contacts 69, the extra oxygen from
etch-stop layer 68 reacts with the metal of thin contact layer 67
and converts it into a high oxygen content, low conductive layer in
the channel area. A series of organic and inorganic etch-stop
materials with oxygen donating function have been disclosed in
copending U.S. patent application entitled "METAL OXIDE TFT WITH
IMPROVED SOURCE/DRAIN CONTACTS", Ser. No. 12/155,749 (4674-A23)
included herein by reference. Examples of photopatternable organic
etch-stop with oxygen donating function include PMMA, polyimide,
and PMGi. More genrally, the organic compounds comprising alcohols
(R--OH), eithers (R--O--R), ketones (R--CO--R), aldehydes
(R--CO--H), carboxylic acids (R--COOH), esters (R-coo-R), acid
anhydrides (R--Co--O--Co--R), and amides (R--C(O)--NR) may be used.
In the expressions above "R" represents an organic group. Epoxides
also fall into this category, they are a special type of ethers in
which the oxygen atom is part of a ring of three atoms.
[0034] In addition to InAlZnO, metal oxide passivation layer 66 can
also be made by blending (or alloying) InZnO with a metyal oxide
having "amphiprotic" properties: which means the corresponding
metal and the metal oxide react with a strong base, such as KOH or
NaOH, and has a substantially faster etching rate than
In.sub.2O.sub.3 and ZnO.sub.2. Examples of such metal oxides
include B--O, Y--O. Moreover, In-x-Zn--O with x in the 3.sup.rd or
4.sup.th column of the periodic table (such as B, Si, Ge) can also
be used for the passivation layer and can be etched with KOH or
NaOH.
[0035] Turning now to FIG. 7, another example is illustrated of a
MOTFT 70 with improved operational stability and high mobility, in
accordance with the present invention. MOTFT 70 includes a
substrate 71 with a bottom gate 72 patterned in the upper surface.
A gate dielectric layer 73 is deposited over gate 72 and portions
of the upper surface of substrate 71 not covered by gate 72. It has
been identified that positive bias stress instability is caused by
oxygen movement from the gate dielectric interface to the
conduction channel leading to a positive shift of threshold
voltage. An example of this positive shift is illustrated in FIG. 2
by curve 27.
[0036] In the example of a MOTFT with improved operational
stability and high mobility of FIG. 7, to prevent the movement of
oxygen from gate dielectric 73, MOTFT 70 includes a very thin film
of oxygen bonding metal, designated 75, positioned at the interface
with an active layer 74. Thin film 75 is, for convenience and, as
explained below, can be deposited in situ with the other films
included in active layer 74, considered a portion of active layer
74. An etch-stop layer 78 is provided on the upper surface of
active layer 74 and defines the channel area in active layer 74.
Source/drain metal contacts 79 are deposited on either side of
etch-stop layer 78 to complete MOTFT 70. Metal film 75 is deposited
with a thickness on the order of a single molecular layer to a few
(i.e. less than 5) molecular layers and includes metals chosen so
that they have a stable oxide, such as Al, Si, B, Ta, Mg, Ti, and
the like. Other metals with metal-oxygen bond strength larger than
100 kcal/mol can also be used. Generally, the metal tightly bonding
the oxygen forms a metal oxide that is electrically nonconductive
so that only active layer 74 conducts current between source/drain
contacts 79.
[0037] Excess oxygen at the interface of metal film 75 with gate
dielectric 73 is then tightly bound by metal atoms in metal film 75
and forms a stable metal oxide bond which eliminates the extra
oxygen atoms and other impurity ions and prevents them from moving
into the channel or active layer 74. Thus, the threshold voltage
for MOTFT 70 is stabilized under high positive biasing fields. By
properly tuning the thickness of metal film 75, and therefore the
number of metal atoms, the extra oxygen and other cat ions at gate
dielectric 73 can be balanced.
[0038] In a specific example of the above improved operational
stability and high mobility MOTFT, a thin Ti layer was deposited by
DC sputtering process in the same chamber used for the following
channel layers. The nominal thickness of the Ti layer was 1.2 nm.
With an InZnO (In:Zn ratio=1:1) channel layer of 20 nm and a
passivation layer made of InAlZnP (In:Al:Zn ratio of 1:1:1), a high
mobility TFT was achieved with negligible V.sub.th shift in both a
forward bias field of +20 mV/cm and a negative bias field of -20
mV/cm at 60.degree. C.
[0039] It should be noted that the MOTFT structures disclosed above
can be achieved without additional tools. For example, after
completing the gate layer process and gate dielectric deposition
(such as SiO.sub.2, SiN, Al.sub.2O.sub.3, or HfO), the substrate
(either glass, plastic, or stainless steel sheet) can be loaded
into a sputter tool with multiple chambers or a chain type sputter
tool with multiple target positions. The thin film of oxygen
bonding metal and the multiple films of the active layer can all be
deposited in one pumping down (i.e. in situ) without a vacuum
break. The multiple layers can be processed in different chambers
or at different target positions in the same chamber. As an
alternative process, the thin film of oxygen bonding metal can be
achieved by means of a coating process with a solution comprising
organo-metallic molecules comprising the corresponding metal. The
thin film of oxygen bonding metal can alternatively be achieved by
a reduction process in a chamber with inert gas or in a vacuum. In
this approach, one sputter source and power supply in the sputter
tool can be saved.
[0040] The present invention provides a new and improved MOTFT with
improved operational stability and high mobility and new and
improved methods of fabricating MOTFTs with improved operational
stability and high mobility. Also, the present invention provides
new and improved methods and apparatus for reducing the V.sub.th
shift under negative and positive bias temperature stress in a
MOTFT.
[0041] Various changes and modifications to the embodiment herein
chosen for purposes of illustration will readily occur to those
skilled in the art. To the extent that such modifications and
variations do not depart from the spirit of the invention, they are
intended to be included within the scope thereof which is assessed
only by a fair interpretation of the following claims.
[0042] Having fully described the invention in such clear and
concise terms as to enable those skilled in the art to understand
and practice the same, the invention claimed is:
* * * * *