Title: PARTICLES FOR USE IN CMP SLURRIES AND METHOD FOR PRODUCING THEM
Cross-Reference to Related Application
[0001] This application is a continuation-in-part of Application Serial No.
09/992,485 filed November 16, 2001.
Field of Invention
[0002] The present invention provides a process for producing abrasive
particles and abrasive particles produced according to the process.
Background of the Invention
[0003] Chemical-mechanical polishing (CMP) slurries are used, for
example, to planarize surfaces during the fabrication of semiconductor chips
and the like. CMP slurries typically include reactive chemical agents and
abrasive particles dispersed in a liquid carrier. The abrasive particles perform
a grinding function when pressed against the surface being polished using a
polishing pad.
[0004] It is well known that the size, composition, and morphology of the
abrasive particles used in a CMP slurry can have a profound effect on the
polishing rate. Over the years, CMP slurries have been formulated using
abrasive particles formed of, for example, alumina (Al203), eerie oxide (Ce02),
iron oxide (Fe203), silica (Si02), silicon carbide (SiC), silicon nitride (Si3N4), tin
oxide (Sn02), titania (Ti02), titanium carbide (TiC), tungstic oxide (W03), yttria
(Y203), zirconia (Zr02), and combinations thereof. Of these oxides, eerie
oxide (Ce02) is the most efficient abrasive in CMP slurries for planarizing
silicon dioxide insulating layers in semiconductors because of its high
polishing activity.
[0005] Calcination is by far the most common method of producing
abrasive particles for use in CMP slurries. During the calcination process,
precursors such as carbonates, oxalates, nitrates, and sulphates, are
converted into their corresponding oxides. After the calcination process is
complete, the resulting oxides must be milled to obtain particle sizes and
distributions that are sufficiently small to prevent scratching.
[0006] The calcination process, although widely used, does present
certain disadvantages. For example, it tends to be energy intensive and thus
relatively expensive. Toxic and/or corrosive gaseous byproducts can be
produced during calcination. In addition, it is very difficult to avoid the
introduction of contaminants during the calcination and subsequent milling
processes. Finally, it is difficult to obtain a narrow distribution of appropriately
sized abrasive particles.
[0007] It is well known that CMP slurries containing contaminants and/or
over-sized abrasive particles can result in undesirable surface scratching
during polishing. While this is less critical for coarse polishing processes, in
the production of critical optical surfaces, semiconductor wafers, and
integrated circuits, defect-free surfaces are required. This is achievable only
when the abrasive particles are kept below about 1.0 μm in diameter and the
CMP slurry is free of contaminants. The production of abrasive particles
meeting these requirements by conventional calcination and milling
techniques is extremely difficult and often not economically feasible.
[0008] An alternative method of forming abrasive particles for use in CMP
slurries is hydrothermal synthesis, which is also known as hydrothermal
treatment. In this process, basic aqueous solutions of metal salts are held at
elevated temperatures and pressures for varying periods of time to produce
small particles of solid oxide suspended in solution. A method of producing
eerie oxide (Ce02) particles via hydrothermal treatment is disclosed, for
example, in Wang, U.S. Pat. No. 5,389,352.
[0009] The production of abrasive particles by hydrothermal treatment
provides several advantages over the calcination/milling process.
Unfortunately, however, abrasive particles formed by conventional
hydrothermal treatment processes tend not to provide desired high polishing
rates.
Summary of Invention
[0010] The present invention provides a process for producing abrasive
particles suitable for use in chemical-mechanical polishing slurries. The
process according to the invention comprises mixing a crystallization
promoter such as titanium (IV) isopropoxide with a cerium compound and a
solvent, optionally adjusting the pH to greater than 7.0 using one or more
bases, and subjecting the mixture to hydrothermal treatment at a temperature
of from about 60°C to about 700°C to produce particles. Although the precise
mechanism is not yet precisely understood, the presence of a crystallization
promoter in the solution during hydrothermal treatment results in the
formation of particles with larger than expected crystallite sizes. Particles
formed in this manner polish surfaces at a much higher rate than particles
formed by conventional hydrothermal processes.
[0011] The foregoing and other features of the invention are hereinafter
more fully described and particularly pointed out in the claims, the following
description setting forth in detail certain illustrative embodiments of the
invention, these being indicative, however, of but a few of the various ways in
which the principles of the present invention may be employed.
Brief Description of the Drawings
[0012] Fig. 1 is a graph showing the particle size distribution of particles
formed in Example 1.
Detailed Description of Preferred Embodiments
[0013] The present invention provides a process for producing abrasive
particles suitable for use in chemical-mechanical polishing slurries without the
need for calcination and/or milling. The process comprises mixing a
crystallization promoter with a cerium compound and a solvent, optionally
adjusting the pH to higher than 7.0 using one or more bases, and subjecting
the mixture to hydrothermal treatment at a temperature of from about 60°C to
about 700°C to produce particles.
[0014] The preferred cerium compound for use in the method according to
the invention is (NH4)2Ce(N03)6 (ammonium cerium (IV) nitrate). However, it
will be appreciated that other cerium compounds can also be used. The
valence of the cerium in the cerium compound is not per se critical, but eerie
(IV) compounds are preferred over cerous (III) compounds. Suitable cerium
compounds for use in the invention include, for example, cerium nitrate,
cerium chloride, cerium sulfate, cerium bromide, and cerium iodide.
[0015] The mixture must also comprise one or more crystallization
promoters. The presently most preferred crystallization promoter is a titanium
compound, namely Ti[OCH(CH3)2)]4 (titanium (IV) isopropoxide), but other
titanium compounds can be also used, such as, for example, titanium
chloride, titanium sulfate, titanium bromide, and titanium oxychloride.
Compounds of metals other than titanium can also be used as crystallization
promoters, as can non-metallic compounds such as nitrogenous cyclic
polymers, poly glycols, alcohols, and ketones. In some cases, the
crystallization promoter can also serve as the solvent. Use of a crystallization
promoter is essential in order to obtain particles having a relatively large
crystallite size.
[0016] As noted above, it is possible to use compounds of metals other
than titanium such as alkaline earth metals (group IIA of the periodic table),
transition metals (element 21 , scandium, through element 29, copper;
element 39, yttrium, through element 47, silver; element 57, lanthanum,
through element 79, gold; and element 89, actinium, and higher), aluminum,
zinc, gallium, germanium, cadmium, indium, tin, antimony, mercury, thallium,
lead, bismuth, and polonium. Scandium compounds, in particular, can be
used to produce cerium oxide (Ce02) particles according to the process of the
invention that have relatively large crystallite sizes. However, for reasons that
are presently unknown, particles formed using scandium compounds as
crystallization promoters are not as effective as abrasives in CMP polishing
applications as compared to particles formed using titanium compounds as
crystallization promoters.
[0017] One or more bases can be optionally added to raise the pH of the
mixture to greater than 7.0 and assist in the formation of a mixture having a
gel-like consistency. Suitable bases include, for example, ammonium
hydroxide, potassium hydroxide, organoamines such as ethyl amine and
ethanol amine, and/or polyorganoamines such as polyethylene imine. The
gel-like mixture formed upon adding a base will break down into small
particles upon rapid stirring.
[0018] Other compounds such as urea, for example, can be used as
precursors for a base. Urea does not act as a base until it is heated, so it
does not tend to form a gel-like mixture when added, but rather will form a
clear solution. Moreover, when urea is used, the pH of the mixture will
generally not be greater than 7.0.
[0019] The mixture, whether in the form of a gel or a clear solution, is then
subjected to hydrothermal treatment. This is typically accomplished by
heating the mixture in a sealed stainless steel vessel to a temperature of from
about 60°C to about 700°C for a period of time of from about 10 minutes to
many hours. At the completion of the reaction, the stainless steel vessel can
be quenched in cold water, or it can be permitted to cool gradually over time.
The mixture can be, but need not be, stirred during hydrothermal treatment. It
is also possible to carry out the reaction in an autoclave unit with constant
stirring.
[0020] Testing has shown that the average particle size (diameter) of the
particles formed during the hydrothermal treatment can be controlled by
varying the initial concentration of the cerium compound, with higher initial
cerium ion concentrations tending to produce particles having a larger
average particle size. The use of precursors of bases such as urea tends to
produce smaller particles. Reaction time, temperature, and pH appear to
have little or no effect on particle size. A range of particle sizes from about 5
nm to about 10,000 nm can be obtained via the process, but particles having
an average diameter within the range of from about 50 nm to about 250 nm
are most preferred.
[0021] Although the mechanism is not fully known at this time, for some
reason the presence of a crystallization promoter such as Ti[OCH(CH3)2)]4
(titanium (IV) isopropoxide) is critical in order to produce abrasive particles
having a large crystallite size, which can be determined using well-known X-
ray diffraction methods. For example, when subjected to identical
hydrothermal conditions (i.e., temperature, time, pH, etc.), a solution
containing a titanium (IV) isopropoxide crystallization promoter produced
particles having an average crystallite size of 21 OA whereas a solution
containing no titanium (IV) isopropoxide crystallization promoter produced
particles having a an average crystallite size of only 42A. For some reason,
the presence of a crystallization promoter in the solution accelerates the
crystal growth of crystallites during hydrothermal treatment, which is a
desirable attribute for abrasive particles used in CMP slurries. Tests have
shown that CMP slurries formed using particles having larger crystallite sizes
tend to polish surfaces such as tetraethoxyorthosilicate (TEOS) silicon dioxide
films at a much higher rate than CMP slurries formed using particles having
smaller crystallite sizes.
[0022] The abrasive particles formed in accordance with the method of the
invention, in addition to exhibiting a crystallite size of greater than about
20θA, predominantly comprise cerium oxide (Ce02) having a cubic crystal
structure. Elemental analysis of abrasive particles formed using a titanium
compound as a crystallization promoter show the presence of titanium atoms
in the cubic crystal structure. There is no titanium dioxide observed by X-ray
diffraction, and no anatase or rutile crystal structure. It is hypothesized that
the titanium atoms are incorporated into the cubic cerium oxide crystal
structure, replacing cerium atoms in such structure. This same phenomenon
is noted when compounds of metals other than titanium are used as
crystallization promoters. When a crystallization promoter selected from the
group consisting of nitrogenous cyclic polymers, poly glycols, alcohols, and
ketones is used, the cerium oxide particles will exhibit a cubic crystal lattice
structure wherein carbon atoms obtained from the crystallization promoter are
incorporated into the cubic crystal lattice structure.
[0023] It will be appreciated that certain metallic compounds, such as
titanium compounds, tend to rapidly decompose in aqueous media, which
reduces their efficiency in promoting the formation of particles having larger
crystallite sizes. Accordingly, it is preferable for one or more stabilizing
compounds such as, for example, acetyl acetone, to be present with the
crystallization promoters in order to prevent or delay the decomposition of
such compounds. When stabilized in this manner, the crystallization
promoters have sufficient time to homogeneously mix with the cerium
compounds at a molecular level, particularly before a gel-like mixture is
formed upon the addition of one or more bases. Applicants have discovered
that when the crystallization promoters are stabilized in this manner, the
particles formed during hydrothermal treatment tend to have substantially
larger crystallite sizes.
[0024] The particles formed according to the process of the invention are
particularly well suited for use in CMP slurries. CMP slurries can be formed
using the particles as obtained via the process or by adding water, acid
and/or base to adjust the abrasive concentration and pH to desired levels.
Alternatively, the abrasive particles formed according to the invention can be
bonded to a polishing pad.
[0025] Surfaces that can be polished using abrasive particles according to
the invention include, but are not limited to TEOS silicon dioxide, spin-on
glass, organosilicates, silicon nitride, silicon oxynitride, silicon, silicon carbide,
computer memory hard disk substrates, silicon-containing low-k dielectrics,
and silicon-containing ceramics. The abrasive particles according to the
invention are particularly useful for polishing layers in semiconductor devices.
[0026] The following examples are intended only to illustrate the invention
and should not be construed as imposing limitations upon the claims.
Example 1
[0027] In a 1000 ml plastic bottle, 41.6 grams of (NH4)2Ce(N03)6
(ammonium cerium (IV) nitrate) was dissolved in 500 ml deionized H20 (Dl-
water) and 1.2 grams CH3COCH2OCCH3 (acetyl acetone) to form a solution.
2.4 grams of Ti[OCH(CH3)2)]4 (titanium (IV) isopropoxide) was added to the
solution followed by the addition of 36 grams of C2H5NH2 (ethylamine) with
stirring. A sufficient quantity of Dl-water was then added to reach a final
volume of 800 ml. The solution was stirred for 5 minutes and then transferred
to a clean 1000 ml stainless steel vessel. The stainless steel vessel was
closed and sealed, shaken for 5 minutes, and then placed into a furnace and
heated at 300°C for 6.0 hours. The stainless steel vessel was then removed
from the furnace and allowed to cool to room temperature. The reaction
product formed in the vessel was transferred to a clean 1000 ml plastic bottle.
As shown in Fig. 1 , the reaction product consisted of a dispersion of Ce02
(cerium oxide) particles having a narrow size distribution (D50 = 87 nm; D90 =
101 nm; and D10 = 68 nm). The cerium oxide particles had an average
crystallite size of 21 OA.
Example 2
(Comparative Example)
[0028] A dispersion of cerium oxide particles was formed using the same
materials and procedures as set forth in Example 1 , except that no
Ti[OCH(CH3)2)]4 (titanium (IV) isopropoxide) was used. The cerium oxide
particles thus formed had a narrow size distribution (D50 = 89 nm; D90 = 99
nm; and D10 = 72 nm) similar to the cerium oxide particles formed in Example
1 , but the average crystallite size was only 42A.
Example 3
[0029] A dispersion of cerium oxide particles was formed using the same
materials and procedures as set forth in Example 1 , except that no acetyl
acetone (CH3COCH2OCCH3) was used. The cerium oxide particles thus
formed had a narrow size distribution (D50 = 80 nm; D90 = 97 nm; and D10 = 60
nm) similar to the cerium oxide particles formed in Example 1 , but the
average crystallite size was only 9θA.
Example 4
[0030] Four chemical-mechanical polishing slurries were formed using
cerium oxide particles. Slurry A consisted of 100 parts by weight of the
cerium oxide nanoparticle dispersion formed in Example 1. Slurry B was
identical to Slurry A, except that the cerium oxide nanoparticle dispersion
formed in Example 2 was used instead of the cerium oxide nanoparticle
solution formed in Example 1. Slurry C was identical to Slurry A, except that
the cerium oxide nanoparticle dispersion formed in Example 3 was used
instead of the cerium oxide nanoparticle solution formed in Example 1. Slurry
D was identical to Slurry A, except that the cerium oxide nanoparticle
dispersion comprised conventional calcined cerium oxide (Ferro Electronic
Material Systems SRS-616A) having an average particle size of D50 = 141 nm
dispersed in water at a pH of 10.0. Identical TEOS Si02 (silicon dioxide)
wafers were polished using Slurries A, B, C, and D, respectively. The
polishing was performed using a Strasbaugh 6EC polisher, a Rodel IC1000
pad with Suba IV backing at a down pressure of 3.2 psi, and a table rotation
speed of 60 rpm, and slurry flow rate of 150 ml/min. The wafer polished using
Slurry A had a Si02 removal rate of 3500 A/min and produced a surface
having a root-mean-square average roughness of O.δA. The wafer polished
using Slurry B had a Si02 removal rate of 85 A/min and produced a surface
having a root-mean-square average roughness of 1.θA. The wafer polished
using Slurry C had a Si02 removal rate of 1875 A/min and produced a surface
having a root-mean-square average roughness of 2.0A. And, the wafer
polished using Slurry D had a Si02 removal rate of 4200 A/min and produced
a surface having a root-mean-square average roughness of 3.0A.
Example 5
[0031] 32.34 grams of ammonium cerium (IV) nitrate was dissolved in 50
ml Dl-water in a 100 ml beaker and heated to 90°C under stirring to form an
aqueous solution. Another solution containing 0.02 grams polyvinyl
pyrrolidone (PVP) having a weight average molecular weight of about 29,000
admixed in 380 grams of 6M KOH in a 500 ml beaker was heated to 90°C.
The aqueous cerium solution was then added to the KOH solution under
constant stirring for 30 minutes. The temperature was kept at 90°C. A white
precipitate was filtered off and washed with water until the pH of the filtrate
was below 10. The precipitate was then dispersed in Dl-water to make a total
volume of 100ml, ultrasonicated for 5 minutes and transferred into a 150 ml
steel vessel and sealed. The steel vessel was then placed in a pre-heated
oven at 250°C for 6 h for hydrothermal treatment. At the end of the
hydrothermal treatment, the vessel was quenched in cold water to room
temperature and the slurry was removed. The so-obtained cerium oxide
particles had an average particle diameter D50 of 300 nm and an average
crystallite size of 130A.
Example 6
[0032] The same process as described in Example 5 was repeated except
that PVP was replaced with 0.02 gram of polyethylene glycol having a weight
average molecular weight of about 600. The so-obtained cerium oxide
particles had an average particle diameter D50 of 100 nm and an average
crystallite size of 150A.
Example 7
[0033] 50 grams of ammonium cerium (IV) nitrate was dissolved in 50 ml
Dl-water in a 100 ml beaker and heated to 90°C under stirring to form an
aqueous cerium solution. Another solution comprising a mixture of 139.32
grams KOH, 234.09 grams Dl-water, 21.465 grams methanol, and 10.125
grams acetone was heated to 90°C in a 500 ml beaker. The aqueous cerium
solution was then added to the KOH solution under constant stirring for 30
minutes. The temperature was kept at 90°C. A white precipitate was filtered
off and washed with water until the pH of the filtrate was below 10. The
precipitate was then dispersed in water to make a total volume of 100ml,
ultrasonicated for 5 minutes and transferred into a 150 ml steel vessel and
sealed. The steel vessel was then placed in a pre-heated oven at 250°C for 6
hours for hydrothermal treatment. At the end of the hydrothermal treatment,
the vessel was quenched in cold water to room temperature and the slurry
was removed. The so-obtained cerium oxide particles had an average
particle diameter D50 of 110 nm and an average crystallite size of 130A.
Example 8
[0034] 22.3 grams of ammonium cerium (IV) nitrate was dissolved in 40 ml
Dl-water in a 100ml beaker. Then, 2.59 grams of a mixture solution
containing 1.177 grams of acetyl acetone and 1.413 grams of titanium (IV)
isopropoxide was added into the ammonium cerium (IV) nitrate solution under
stirring. In another beaker, 20.7 grams of concentrated ammonium hydroxide
(57 wt% NH4OH) was mixed with 20 grams of Dl-water. The solution
containing ammonium cerium (IV) nitrate and titanium (IV) isopropoxide was
then added into the ammonium hydroxide solution under stirring, stirred for
another 3 minutes, and additional Dl-water added to a total final volume of
100 ml. The mixture was ultrasonicated for 5 minutes, transferred to a 150 ml
steel vessel, and tightly sealed. The steel vessel was then placed in an oven
preheated at 300°C for 6 hours for hydrothermal treatment. At the end of the
hydrothermal treatment, the vessel was quenched in cold water to room
temperature and the slurry was removed. The so-obtained cerium oxide
particles had an average particle diameter D50 of 97 nm and an average
crystallite size of 26θA.
Example 9
[0035] 71.6 grams of ammonium cerium (IV) nitrate and 35.1 grams of
urea were dissolved in 700 ml Dl-water in a 1000 ml beaker. Then, 7.52
grams of a mixture solution containing 3.418 grams of acetyl acetone and
4.102 grams of titanium (IV) isopropoxide was added into the ammonium
cerium (IV) nitrate solution under stirring. Additional Dl-water was added to
mixture to a total final volume of 1286 ml. Finally, the mixture was transferred
to a 2000 ml steel vessel and tightly sealed. The sealed steel vessel was
then placed in an oven preheated at 300°C for 3 hours for hydrothermal
treatment. At the end of the hydrothermal treatment, the vessel was
quenched in cold water to room temperature and the slurry was removed.
The so-obtained cerium oxide particles had an average diameter D50 of 860
nm and an average crystallite size of 2480A.
Example 10
[0036] The process as described in Example 9 was repeated except that
ammonium cerium (IV) nitrate was replaced with 56.4 grams of Ce(N03)3
(cerium (III) nitrate). The so-obtained cerium oxide particles had an average
diameter D50 of 910 nm and an average crystallite size of 2220A.
[0037] Additional advantages and modifications will readily occur to those
skilled in the art. Therefore, the invention in its broader aspects is not limited
to the specific details and illustrative examples shown and described herein.
Accordingly, various modifications may be made without departing from the
spirit or scope of the general inventive concept as defined by the appended
claims and their equivalents.