Journal of The Electrochemical Society, 148 ͑12͒ F207-F211 ͑2001͒
F207
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013-4651/2001/148͑12͒/F207/5/$7.00 © The Electrochemical Society, Inc.
Minimizing the Effects of Hardware Marginality on Charging
Damage during Plasma-Enhanced Chemical Vapor
Dielectric Deposition
Antonio Cacciatoz
Philips Semiconductors, MOS 4 YOU, 6534 AE Nijmegen, The Netherlands
In this paper, Kelvin-probe measurements, antenna transistors, and electrically programmable read-only memory cells are used to
minimize the influence of hardware marginality on charging damage during plasma-enhanced chemical vapor deposition of
dielectric films. It is shown that charging during tetraethosiloxane ͑TEOS͒ deposition can be reduced by increasing the deposition
pressure and optimizing the plasma ramp-down after deposition. It is also demonstrated that differences in the charging perfor-
mance between tools from different vendors during the deposition of silicon-rich oxides can be smoothed out if a double radio
frequency process replaces the traditional single radio frequency deposition.
©
2001 The Electrochemical Society. ͓DOI: 10.1149/1.1414289͔ All rights reserved.
Manuscript received March 15, 2001. Available electronically November 2, 2001.
Plasma processes are widely used in microelectronic manufactur-
ing for anisotropic etching, surface cleaning, and low-temperature
plasma-enhanced chemical vapor deposition ͑PECVD͒ of thin
gas. After deposition, a ramp-down step was performed using a
He ϩ O plasma ͑5 s at 200 W, 8 Torr, 1200 sccm He, 1000 sccm
2
O ͒. Variants to the standard process were obtained varying the
2
1
films. During plasma processing, wafers are subjected to the direct
deposition pressure in the range from 5 to 15 Torr, the oxygen flow
in the range 500 to 2000 sccm, the deposition temperature, and the
TEOS flow. For all the variants, the thickness of the TEOS layer was
bombardment of ions, electrons, and photons. In uniform plasma the
ion and electron conduction locally balance each other over the rf
2
cycle. In this case, the surface potential stays close to that of the
500 nm, i.e., the same of the standard process.
substrate. In nonuniform plasma, however, the situation differs sig-
nificantly. Ion and electron currents do not balance locally during the
rf cycle, although there is a net balance over the electrode as a
whole. In this case, charges ͑positive or negative depending on spe-
cific ratio between positive and negative currents͒ start to accumu-
late on the wafer regions covered by insulating films. The charge
buildup continues until the electric field across gate oxides reaches
values high enough to allow Fowler-Nordheim ͑FN͒ tunneling of
charges. This causes what is usually called plasma charging damage,
i.e., trap formation, wear out, and premature breakdown of thin gate
oxides. Moreover, it increases the probability of charge trapping in
the oxide. As a consequence, shifts of the threshold voltage, leakage,
degraded circuit speed, and deterioration of transistor matching may
occur. As device dimensions and gate oxide thicknesses are scaled
SILOX deposition.—300 nm PECVD silicon-rich oxide films were
deposited on 200 mm wafers. Prior to SILOX deposition, EPROM
cells were fabricated on the same wafers using a 0.35 m comple-
mentary metal oxide semiconductor ͑CMOS͒ technology. Deposi-
tion was carried out at a temperature of 400°C, a pressure of 2.5
Torr, an rf power of 250 W and using a SiH ϩ N O gas chemistry.
4
2
The deposition time was ca. 15 s. Unlike for TEOS films, after
deposition the plasma was switched off without a He ϩ O plasma
2
ramp-down. SILOX layers were deposited using either batch or
single-wafer PECVD reactors. In the case of the batch reactor, the
chamber allowed the deposition of six wafers at the same time. The
SiH flow was 130 and 300 sccm for the single-wafer and batch
4
3
4
reactor, respectively. The N2O flow was 800 sccm ͑single-wafer re-
actor͒ or 9500 sccm ͑batch reactor͒. In some cases, in addition to the
down, charging becomes an increasing reliability or yield concern.
To limit charging damage, tight control of plasma uniformity and
knowledge of the interaction among plasma, hardware, and process
1
3.5 MHz rf power used to decompose the SiH ϩ N O gas mixture
4 2
5
and ignite the plasma, a low-frequency ͑10 kHz͒ rf power was ap-
plied to the wafer susceptor to enhance the ion bombardment on the
as-deposited film. Double rf recipes are used in microelectronic
manufacturing because the ion bombardment improves the quality
settings are mandatory. In this paper, these issues are addressed by
6
using fast-feedback noncontact Kelvin-probe measurements, an-
tenna transistors, and electrically programmable read-only memory
cells ͑EPROM͒7 to measure charging during plasma-enhanced
1
0
͑stability and density͒ of the insulating layers.
chemical vapor deposition of two materials widely used in micro-
electronic manufacturing for interlayer and intermetal insulation, tet-
Charging measurements.—Kelvin probe.—During PECVD
8
9
raethosiloxane ͑or TEOS͒ and the silicon-rich oxide ͑or SILOX͒.
deposition of insulating layers, charges may accumulate in the bulk
as well as on the surface of the wafer if the plasma in unstable.
These charges change the surface potential of the wafer. Therefore, a
measurement of the wafer surface potential can be used to detect
charging. In this work, the surface potential after PECVD TEOS
deposition was measured using the Kelvin probe technique. The
probe consists of a noncontact sensor that detects the ac signal in-
duced by an oscillating shutter positioned between the electrode and
the wafer surface. Measurements were carried out applying different
dc biases across the sensing electrode and a grounded electrode until
the ac voltage is reduced to zero. The bias at which the ac voltage is
zero is equivalent to the wafer surface potential. A more detailed
description of probe functioning can be found in Ref. 11. Kelvin
probe measurements were performed using the plasma damage
monitor system manufactured by Semiconductor Diagnostics, Inc.
The distribution of the surface potential on the wafer was evaluated
by measuring 6000 points per wafer.
In particular, the relation between plasma ramp-down, reactor archi-
tecture ͑single-wafer or batch͒, and charging is investigated. Pos-
sible ways to optimize the deposition process in order to minimize
the influence of process-hardware marginality on charging are also
discussed.
Experimental
Dielectric deposition.—TEOS deposition.—SiO layers ͑500 nm
2
thick͒ were deposited on 200 mm wafers using plasma-enhanced
chemical vapor deposition ͑PECVD͒ by decomposition of tetra-
8
ethosiloxane, Si͑OC H ͒ , better known as TEOS, Si͑OC H ͒
2
5 4
2
5 4
ϩ O → SiO ϩ CO ϩ OH. The deposition was carried out for 45
2
2
s at 400°C using an rf power of 675 W and a deposition pressure of
8
1
Torr. During deposition, the TEOS and O flows were 1200 and
000 sccm, respectively. Helium ͑1200 sccm͒ was used as a carrying
2
Threshold voltage shift.—Surface potential measurements have been
compared with threshold voltage measurements of n- and p-channel
z
E-mail: antonio.cacciato@philips.com