Method for selective etching of nanostructures
11424130 · 2022-08-23
Assignee
Inventors
Cpc classification
H01L29/775
ELECTRICITY
H01L29/66439
ELECTRICITY
B82Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B81C1/00626
PERFORMING OPERATIONS; TRANSPORTING
H01L21/3086
ELECTRICITY
H01L2029/7858
ELECTRICITY
B82Y40/00
PERFORMING OPERATIONS; TRANSPORTING
H01L29/785
ELECTRICITY
International classification
H01L29/06
ELECTRICITY
H01L29/775
ELECTRICITY
H01L29/66
ELECTRICITY
H01L21/306
ELECTRICITY
B81C1/00
PERFORMING OPERATIONS; TRANSPORTING
B82Y10/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to a method for selective etching of a nanostructure (10). The method comprising: providing the nanostructure (10) having a main surface (12) delimited by, in relation to the main surface (12), inclined surfaces (14); and subjecting the nanostructure (10) for a dry etching, wherein the dry etching comprises: subjecting the nanostructure (10) for a low energy particle beam (20) having a direction perpendicular to the main surface (12); whereby a recess (16) in the nanostructure (10) is formed, the recess (16) having its opening at the main surface (12) of the nanostructure (10).
Claims
1. A method for forming a nanostructure, the method comprising: providing a substrate having a first layer and a resist layer, wherein the first layer is between the resist layer and the substrate; lithography patterning the resist layer, thereby exposing areas of the first layer; etching the exposed areas of the first layer, thereby forming first recesses in the first layer; removing the remaining resist layer, thereby forming ridges of the first layer between the first recesses of the first; subjecting the first layer to a first dry etching process, wherein the first dry etching process comprises: subjecting the first layer to a particle beam; whereby selective etching of the ridges of the first layer relative to walls of the first recesses in the layer is achieved such that second recesses in the first layer are formed, the second recesses in the first layer having openings at the ridges of the first layer; thereby a nanostructure consisting of a plurality of first fins delimited by the first and second recesses in the first layer are formed, the first fins having a first pitch.
2. The method according to claim 1, wherein the provided substrate further comprises a hardmask layer arranged directly beneath the first layer, wherein the acts of etching the exposed areas of the first layer and subjecting the first layer to the dry etching are performed such that the hardmask layer is exposed.
3. The method according to claim 2, wherein the provided substrate further comprises a second layer, wherein the hardmask layer is arranged in between the first and second layers, wherein the method further comprises: removing the hardmask layer between the first fins, thereby exposing areas of the second layer; etching the exposed areas of the second layer, thereby forming first recesses in the second epitaxially grown layer; removing the first fins and the remaining hardmask layer, thereby forming ridges of the second layer between the first recesses in the second epitaxially grown layer; subjecting the second layer for a second dry etching process, wherein the second dry etching process comprises: subjecting the second layer to a particle beam; whereby selective etching of the ridges of the second layer relative to walls of the first recesses in the second layer is achieved such that second recesses in the second layer are formed, the second recesses having openings at the ridges of the second layer; thereby a nanostructure consisting of a plurality of second fins delimited by the first and second recesses in the second layer are formed, the second fins having a second pitch being narrower than the first pitch.
4. The method according to claim 3, wherein the second pitch is half of the first pitch.
5. The method according to claim 1, wherein the first dry etching process is a maskless Atomic Layer Etching process comprising a first cyclic etch process where each cycle comprises subjecting the first layer to surface modification and subjecting the first layer to the particle beam.
6. The method according to claim 5, wherein etch steps in the first cyclic etch process are separated with purge steps in such a way that the etch pulses overlap in time and space such that purge steps are reduced or removed.
7. The method according to claim 5, wherein the first cyclic etch process comprises a parallel continuous etch process and the etch partly saturates with time during process steps.
8. The method according to claim 5, wherein the first cyclic etch process comprises a parallel continuous deposition process and the etch partly saturates with time during process steps.
9. The method according to claim 3, wherein the second dry etching process is a maskless Atomic Layer Etching process comprising a second cyclic etch process where each cycle comprises subjecting the second layer to surface modification and subjecting the second epitaxially grown layer to the particle beam.
10. The method according to claim 9, wherein etch steps in the second cyclic etch process are separated with purge steps in such a way that the etch pulses overlap in time and space such that purge steps are reduced or removed.
11. The method according to claim 9, wherein the second cyclic etch process comprises a parallel continuous etch process and the etch partly saturates with time during process steps.
12. The method according to claim 9, wherein the second cyclic etch process comprises a parallel continuous deposition process and the etch partly saturates with time during process steps.
13. The method according to claim 1, further comprising passivating or coating the nanostructure by an oxide, nitride or gas phase doping before the first dry etching process.
14. The method according to claim 3, further comprising passivating or coating the nanostructure by an oxide, nitride or gas phase doping before the second dry etching process.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The above and other aspects of the present invention will now be described in more detail, with reference to appended drawings showing embodiments of the invention. The figures should not be considered limiting the invention to the specific embodiment; instead they are used for explaining and understanding the invention.
(2) As illustrated in the figures, the sizes of layers and regions are exaggerated for illustrative purposes and, thus, are provided to illustrate the general structures of embodiments of the present invention. Like reference numerals refer to like elements throughout.
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DETAILED DESCRIPTION
(14) The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and to fully convey the scope of the invention to the skilled person.
(15) The present invention is directed towards selective etching of nanostructures. The inventors have surprisingly discovered that by subjecting a nanostructure, with in relation to each other inclined surfaces, for dry etching with a particle beam being substantially perpendicular to a main surface of delimited by inclined surfaces, a recess is formed between the inclined surfaces. The particle beam etches the structure surface less when the angle towards the particle beam is smaller or larger than 90°. Thus, the inclined surfaces are left substantially un-etched and the main surface, intermediate the inclined surfaces, is etched.
(16) Dry etching methods suitable for this inventive method of etching with a particle beam are continuous etching methods or cyclic etching methods. Examples of continuous etching methods are low energy particle beam sputtering, for example with Ar ions, and low energy particle beam continuous reactive ion etching, for example with Ar and Cl.sub.2 gases. And examples of cyclic etching methods are Atomic Layer Etching, ALE, and non-ideal ALE. Here non-ideal ALE refers to different processes with process parameters similar to those of ideal ALE but somewhat different, e.g. outside of saturation regions, which means non-self-limiting process behavior. The non-ideal ALE may provide a faster etch process at the expense of process stability and may be preferred in some cases. Below ALE will be used as an example. Before introducing the inventive method, some basics of ALE will be discussed.
(17) ALE has been studied for almost 30 years. Pioneering work was presented in U.S. Pat. No. 4,756,794 A1. ALE has been referred to by different names, such as Plasma Atomic Layer Etching (PALE), Layer-by-Layer Etching, Digital Etching, Single Layer Etching, Atomic Layer Removal, Molecular Bilayer Etching and Thin Layer Etching. Different ALE names and corresponding references has been listed by Kanarik et al. in “Overview of atomic layer etching in the semiconductor industry” J. Vac. Sci. Technol., 33(2), 2015. Until today more than 20 materials have been inspected using ALE including silicon, III-V semiconductor materials, different oxides, 2D materials and some polymers; a list of inspected materials has been listed by Oehrlein et al. in “Atomic layer etching at the tipping point: An overview” Journal of Solid State Science and Technology, 4(6), 2015.
(18) ALE is a cyclic etch process in which a well-defined atomically thin layer is etched in each cycle. ALE is cost-effective for advanced semiconductor devices since the amount of material being removed is readily measured in atomic layers, or even subatomic layers, which provides atomic level control over etching process, this is critical for the leading edge devices. The process is well controlled due to a self-limiting nature of the basic steps in the ALE process.
(19) Typically, the ALE process comprises two major steps: surface modification and removal of the modified surface layer. There are also typically two intermediate steps comprising: purging the remaining gases after the surface modification and purging the remaining byproducts after the removal of the modified layer.
(20) The surface modification may be performed in various ways dependent upon the material of the nanostructure to be etched and what removal process step that is to be used. The surface modification may e.g. be made by one of chemisorption, desorption, conversion or extraction. A well-defined thin layer is formed on the surface by the surface modification. This thin layer is easier to etch than unmodified material, which leads to the selective material removal.
(21) Removal of the modified surface layer may be made in various ways. The most common way is particle bombardment using a particle beam. Typically, the particle beam comprises atoms or molecules of an inert gas, such as argon, AR, or neon, Ne. The atoms or molecules may also be ionized, hence, the particle beam may be an ion beam. The use of a particle beam for removal of the modified surface layer leads to an anisotropic etching process. Other methods used during ALE for removal of the modified surface layer are thermal desorption and chemical reaction, both which are isotropic approaches.
(22) ALE may e.g. be performed using an ICP-RIE system Plasmalab-100, from Oxford Instruments. Other systems that may be used are listed above under the summary of invention section.
(23) The principle of a method according to the present invention for selective etching of nanostructures will now be discussed in connection with
(24) The particle beam has a direction perpendicular to a main surface 12 of the nanostructure 10. The main surface 12 is delimited by at least two, in relation to the main surface 12, inclined surfaces 14. The inclined surfaces 14 may be downwardly or upwardly inclined in relation to the main surface. The inclined surfaces 14 may also be referred to as facets surfaces of the nanostructure 10. Hence, the particle beam has a direction which is substantially perpendicular to the main surface 12 of the nanostructure 10.
(25) It shall be understood that direction of the particle beam in relation to the main surface 12 may deviate by as much as ±10° from being strictly perpendicular and still selective etching will occur. The selective etching will be discussed in more details below.
(26) As mentioned above in the case of ALE, in between
(27) As is illustrated in
(28) It is shall be noted that
(29) It shall be also noted that typically sharp corners 17 of the etched nanostructure 10 will be naturally rounded off during the etch process as shown in
(30) In case of the dry etching being ALE, each cycle of the ALE process also comprises subjecting the nanostructure 10 for surface modification. The surface modification may be any one of chemisorption, deposition, conversion or extraction. In a preferred embodiment the surface modification is made using chemisorption of chlorine gas. For each cycle of the ALE the subjecting of the nanostructure 10 for surface modification is preferably performed before subjecting the nanostructure 10 for the removal of the modified layer.
(31) Typically, each cycle of the ALE process also comprises one or more intermediate steps. Two non-limiting examples of such intermediate steps are: purging the remaining gases after the surface modification and purging the remaining byproducts after the removal of the modified layer.
(32) During the ALE it is believed that particle interaction with a surface of the nanostructure 10 depends on the impingement angle. Further, it is believed that particle interaction with the surface of the nanostructure depends on the energy of the particle beam. The energy of the particle beam is determined by the energy of the incoming particles and on the local electric field at the nanostructure. It is believed that corners of the nanostructure 10, i.e. formed at the crossing between the main and inclined surfaces 12, 14, and the broken edges of the nanowire in the example given in
(33) By continuing the cyclic ALE process, the nanostructure 10 may be split in two nanostructures as shown in
(34) The recess 16 may form a channel in the nanostructure. This is illustrated in
(35) Giving a more detail view on the example disclosed in connection with
(36) The inventive method may be used on a variety of different nanostructures. Some non-limiting examples are: GaP nanowires, Si nanowires. Other examples are structures being exposed to lithographic patterning and (wet or dry) etching.
(37) GaP nanowires may be grown by Metal Organic Vapor Phase Epitaxy, MOVPE, from seed catalyst nanoparticles, e.g. gold seed particles, on GaP substrates. Si nanowires may be grown on Si substrates with random crystallographic orientation. The GaP and Si nanowires may after growth be mechanically transferred to a Si surface and then etched with the inventive method.
(38) The inventive method has been experimentally proven for nanowires having diameter in the interval of 40 nm to 110 nm. However, it is believed that the same operation will occur at smaller diameters down to 10 nm and below. The method may of course also be used for other nanostructures than nanowires. Moreover, the method may be used at larger structures than what was exemplified directly above. The method may be used by ALE or by any other dry etching method using a particle beam for etching.
(39) The inventors have been performing a number of experiments using the inventive method.
(40) In
(41) Further, as is illustrated in
(42) Further, as seen in the SEM image, the part 210 of the GaP nanowire that has not been subjected for the inventive method is still unaffected. This is also illustrated in the schematic cross section of the nanowire taken along the line C-C and shown in
(43) In
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(46) A further division of the structure of
(47) In
(48) These processes have the advantages of only one litho exposure, no deposition required and all etch processes can be performed on one cluster without vacuum break and potentially even without mechanical transfer to another chamber.
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(50) The structure is provided with a substantially planar top surface limited by inclined surfaces.
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(52) For the above mentioned experiments the GaP nanowires were fabricated using gold aerosol particles as growth catalysts on GaP (111) substrates using MOVPE. The detail of GaP nanowires fabrication process can be found elsewhere, see e.g. Dmitry B Suyatin, et al. “Gallium phosphide nanowire array and their possible application in cellular force investigation”; Journal of Vacuum Science and Technology B, 27(6), 3092-3094, 2009. The GaP nanowires were mechanically transferred on a silicon surface before performing the inventive method.
(53) For the above mentioned experiments the Si nanowires were grown on Si substrates with random crystallographic orientation. The detail of Si nanowires fabrication process can be found elsewhere, see e.g. Walter M. Weber, et al. “Silicon nanowires: catalytic growth and electrical characterization”, phys. stat. sol. (b) 243, No. 13, 3340-3345, 2006. The Si nanowires were mechanically transferred on a Silicon surface before performing the inventive method.
(54) Oxford Instruments Plasmalab 100 were used for the ALE process. The surface modification was made using chemisorption of Cl.sub.2. The subsequent removal of the modified surface layer was made using an Ar plasma. During the ALE-process the sample carrier was maintained at room temperature. The cyclic ALE-process was performed by cyclically performing the following four steps with the process parameters listed in connection with each step: a) Surface modification with Cl.sub.2: Ar flow=0 sccm; Cl.sub.2 flow 20 sccm; pressure=30 mTorr; time=20 s. b) Purging: Ar flow=40 sccm; Cl.sub.2 flow 0 sccm; pressure=30 mTorr; time=10 s. c) Removal step with Ar ions: RF 25 W; Ar flow=10 sccm; Cl.sub.2 flow 0 sccm; pressure=3 mTorr; time=10 s. d) Purging: Ar flow=10 sccm; Cl.sub.2 flow 0 sccm; pressure=30 mTorr; time=2 s.
The steps a)-d) where cyclically repeated. The etching rate was established to be approximately 2 Å/cycle. The SEM images was acquired using Hitachi SU8010 and LEO 1560 SEMs.
(55) The above experimental results demonstrate that the method according to this invention e.g. enables splitting of individual transistor channels in a simple and inexpensive way. This may accelerate and facilitate further downscaling of electronic devices.
(56) Overall, the method of nanostructure fabrication using the method according to the present invention is potentially a damage-free dry etch process. Owing to the selectivity of the etching process to etch non-inclined surfaces, the inclined surfaces and corners of nanostructures may be used as a mask and in this way side facets of tapered structures, which can be readily fabricated by e.g., dry etching or epitaxial growth, will provide masking during the atomic layer etching process. This is why this process provides access to fabrication of extremely small structures in a very precise, controlled and efficient way.
(57) The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.
(58) For example, different particles may be used for the particle beam. According to a non-limiting example, the particle beam may comprise Ar ions.
(59) The above listed parameters and instrument were used for the above described experiments. It is however contemplated that the inventive method may be performed using other instruments and/or other parameters as well. For example, the pressures, the flow of Ar, the flow of Cl.sub.2 and/or the times may be varied. Further, the inventive method will also work using other types of surface modification steps and/or other types of removal steps. The surface modification may be made using such gases as Cl.sub.2, BCl.sub.3, O.sub.2, H.sub.2, CF.sub.4, CHF.sub.3, C.sub.2F.sub.6, C.sub.3F.sub.6, C.sub.4F.sub.8, CHF.sub.3, SF.sub.6, NF.sub.3 and mixtures thereof. The choice of gas depends on the material of the nanostructure. The removal of the surface modified layer may be made using other gases than Ar, e.g. other inert gases such as Ne. Using e.g. Ne may be beneficial when processing e.g. nanostructures of silicon since it has a smaller mass than silicon.
(60) In addition, the surface of the nanostructure subjected for dry etching according to the inventive method may be additionally modified before the dry etching process in order to increase the etch selectivity. This modification process may be represented, but not limited, by surface passivation or coating with e.g. oxide coating, nitride coating or gas phase doping.
(61) The method according to the present invention may be used for manufacturing of different nanoscale devices. According to a non-limiting example, the method may be used for recessing FinFET gate channels. According to anther non-limiting example, the method may be used for forming and/or modifying a transistor gate channel, such as a GAAFET nanowire gate channel.
(62) Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.