Methods of forming metal layers using metallic precursors
First Claim
1. A method of forming a metal layer, comprising the steps of:
- chemisorbing a metallic precursor on a substrate, said metallic precursor comprising a metal element and at least one non-metal element that is ligand-bonded to the metal element; and
converting the chemisorbed metallic precursor into the metal layer by removing the at least one non-metal element from the metallic precursor.
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Abstract
Methods of forming metal layers include techniques to form metal layers using atomic layer deposition techniques that may be repeated in sequence to build up multiple atomic metal layers into a metal thin film. The methods include forming a metal layer by chemisorbing a metallic precursor comprising a metal element and at least one non-metal element that is ligand-bonded to the metal element, on a substrate. The metal element may include tantalum. The chemisorbed metallic precursor is then converted into the metal layer by removing the at least one non-metal element from the metallic precursor through ligand exchange. This removal of the non-metal element may be achieved by exposing the chemisorbed metallic precursor to an activated gas that is established by a remote plasma, which reduces substrate damage. The activated gas may be selected from the group consisting of H2, NH3, SiH4 and Si2H6 and combinations thereof. These steps may be performed at a temperature less than about 650° C.
200 Citations
51 Claims
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1. A method of forming a metal layer, comprising the steps of:
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chemisorbing a metallic precursor on a substrate, said metallic precursor comprising a metal element and at least one non-metal element that is ligand-bonded to the metal element; and
converting the chemisorbed metallic precursor into the metal layer by removing the at least one non-metal element from the metallic precursor. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of forming a metal layer, comprising the steps of:
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chemisorbing a first metallic precursor comprising a metal element and at least one non-metal element that is ligand-bonded to the metal element, on a substrate;
converting the chemisorbed first metallic precursor into a first atomic metal layer by removing the at least one non-metal element from the first metallic precursor;
chemisorbing a second metallic precursor that comprises the metal element and the at least one non-metal element that is ligand-bonded to the metal element, on the first atomic metal layer; and
converting the chemisorbed second metallic precursor into a second atomic metal layer by removing the at least one non-metal element from the second metallic precursor;
- View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31)
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17. A method for depositing an atomic layer, the method comprising the steps of:
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a) introducing a metallorganic precursor onto a substrate, the metallorganic precursor including a metal element and bonding elements as reactants, the bonding elements being chemically bonded to the metal element, a part of the bonding elements including a ligand bonding element which is ligand-bonded to the metal element;
b) chemisorbing a part of the reactants on the substrate;
c) removing non-chemisorbed reactants from the substrate; and
d) removing the ligand bonded element of the bonded elements from the chemisorbed reactants, thereby forming a metal-containing solid on the substrate.
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32. A method for forming a thin film by atomic layer deposition, the method comprising the steps of:
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a) introducing gaseous tantalum amine derivative or tantalum halide precursor as reactants onto a substrate;
b) chemisorbing a part of the reactants on the substrate;
c) introducing an inert gas onto the substrate to remove non-chemisorbed reactants from the substrate;
d) introducing any one gas selected from the group consisting of H2, NH3, SiH4, Si2H6 and combinations thereof onto the substrate to remove a ligand-bonded element from the chemisorbed reactants, thereby forming a TaN-containing solid on the substrate; and
e) repeating steps a) to d) in sequence at least once to form a TaN thin film including the TaN-containing solid. - View Dependent Claims (33, 34, 35, 36, 37, 38, 39)
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40. A method for forming a thin film by using an atomic layer deposition, the method comprising the steps of:
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a) forming an insulating layer on a substrate;
b) etching a predetermined portion of the insulating layer to form an opening for exposing a surface portion of the substrate;
c) continuously introducing gaseous tantalum amine derivative or tantalum halide precursor as reactants onto the surface portion of the substrate, the insulating layer and a sidewall of the opening;
d) continuously chemisorbing a part of the reactants on the surface portion of the substrate, the insulating layer and a sidewall of the opening;
e) continuously introducing an inert gas onto the surface portion of the substrate, the insulating layer and a sidewall of the opening to remove the non-chemisorbed reactants from the surface portion of the substrate, the insulating layer and a sidewall of the opening;
f) introducing any one selected from the group consisting of H2, NH3, SiH4, Si2H6, and a combination thereof onto the surface portion of the substrate, the insulating layer and the sidewall of the opening so as to remove a ligand bonded element from the chemisorbed reactants, there by forming a TaN-containing solid; and
g) repeating steps c) to f) at least once to continuously form a TaN thin film from the TaN-containing solid on the surface of the substrate, the insulating layer and the sidewall of the opening. - View Dependent Claims (41, 42, 43, 44, 45, 47, 48, 49, 50, 51)
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46. A method for forming a metal layer, the method comprising the steps of:
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a) forming an insulating layer on a lower structure formed on the substrate;
b) forming an opening for exposing a surface portion of the lower structure by etching a predetermined portion of the insulating layer;
c) continuously introducing gaseous tantalum amine derivative or tantalum halide precursor as reactants onto the surface portion of the lower structure, the insulating layer and a sidewall of the opening;
d) continuously chemisorbing a part of the reactants on the surface portion of the lower structure, the insulating layer and the sidewall of the opening;
e) removing non-chemisorbed reactants from the surface of the lower structure, the insulating layer and the sidewall of the opening by continuously introducing an inert gas onto the surface portion of the lower structure, the insulating layer, and the sidewall of the opening;
f) introducing any one selected from the group consisting of H2, NH3, SiH4, Si2H6, and a combination thereof onto the surface portion of the substrate, the insulating layer and the sidewall of the opening so as to remove a ligand-bonded element from the chemisorbed reactants, thereby forming a TaN-containing solid;
g) repeating steps c) to f) at least once to continuously form a TaN thin film from the TaN containing solid on the lower structure, the insulating layer and the sidewall of the opening; and
h) forming a metal layer including the metal on the TaN thin film filling, the metal layer filling up the opening.
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Specification