Hybrid integrated semiconductor tri-gate and split dual-gate FinFET devices and method for manufacturing
10923399 ยท 2021-02-16
Assignee
Inventors
Cpc classification
H01L21/845
ELECTRICITY
H01L21/782
ELECTRICITY
International classification
H01L21/782
ELECTRICITY
H01L21/84
ELECTRICITY
Abstract
A method for making a tri-gate FinFET and a dual-gate FinFET includes providing a semiconductor on insulator (SOI) wafer having a semiconductor layer over an insulator layer. The method further includes forming a hard mask on the semiconductor layer and patterning the hard mask to form first and second cap portions. The method also includes etching the semiconductor layer to form first and second fins using the first and second cap portions as an etch mask. The method also includes removing the second cap portion to expose the top surface of the second fin and forming a gate dielectric layer on the first and second fins. The method further includes forming a conductive layer over the gate dielectric layer, selectively etching the conductive layer to form first and second gate structures, forming an interlayer dielectric layer over the gate structures, and planarizing the interlayer dielectric layer using the first cap portion as a polish stop.
Claims
1. A method for fabricating an integrated circuit having at least a tri-gate FinFET and a dual-gate FinFET, the method comprising: providing a semiconductor on insulator (SOI) substrate, the SOI substrate comprising a semiconductor layer overlying an insulator layer, the semiconductor layer having a surface region; implanting impurities into the semiconductor layer for a threshold voltage adjustment; forming a hard mask overlying the surface region; patterning the hard mask to form a first hard mask cap portion and a second hard mask cap portion; etching the semiconductor layer using the patterned hard mask as an etch mask to form a first fin and a second fin and expose a contiguous surface of the insulator layer between the first and second fins; removing the second hard mask cap portion overlying the second fin; forming a gate dielectric layer over side surfaces of the first fin and side surfaces and a top surface of the second fin while leaving the first hard mask cap portion uncovered; forming a conductive layer overlying the gate dielectric layer, the conductive layer in direct contact with the first hard mask cap portion and with the exposed contiguous surface of the insulator layer; selectively etching the conductive layer using a photolithographic and etch process to form a first gate structure covering the first hard mask cap portion on the first fin and the side surfaces the first fin and a second gate structure covering the top surface and the side surfaces the second fin; forming an interlayer dielectric layer overlying the first and second gate structures; and removing a top portion of the first and second gate structures by chemical mechanical polishing (CMP) using the first hard mask cap portion as a polish stop, such that the first gate structure is separated into a first gate electrode and a second gate electrode covering the side surfaces of the first fin to form the dual-gate FinFET, and the second gate structure covers the top surface and the side surfaces of the second fin to form the tri-gate FinFET.
2. The method of claim 1, wherein the insulator layer comprises silicon dioxide and the semiconductor layer comprises silicon.
3. The method of claim 1, wherein forming the conductive layer comprises an atomic layer deposition process.
4. The method of claim 1, wherein the first fin has a rectangular cross-section with a width in a range between about 5 nm and about 50 nm and a height in a range between about 5 nm and about 100 nm.
5. The method of claim 1, wherein the second fin has a rectangular cross-section with a width in a range between about 5 nm and about 50 nm and a height in a range between about 5 and about 100 nm.
6. The method of claim 1, wherein forming the first and second fins further comprising annealing in an H.sub.2 ambient at a temperature ranging from about 800 C. to about 1000 C.
7. The method of claim 1, wherein selectively etching the conductive layer comprises: providing an etch mask; patterning the etch mask; etching the conductive layer; and removing the etch mask.
8. The method of claim 1 further comprising: forming elevated source and drain regions; and forming a SiGe layer on the elevated source and drain regions by selective epitaxial growth at a temperature of about 700-800 C. in an ambient of SiH.sub.2Cl.sub.2+HCl+GeH.sub.4.
9. The method of claim 8, wherein the SiGe layer has a thickness of about 100 nm to about 500 nm and a germanium content of about 10-30%.
10. The method of claim 1 further comprising: forming contact regions, the contact regions comprising tungsten plugs; and forming interconnects, the interconnects comprising copper interconnect lines.
11. The method of claim 1, wherein the second gate structure contacts at least three surfaces of the second fin.
12. The method of claim 1, wherein the first gate structure comprises a first gate electrode and a second electrode, the first and second electrodes being disposed on opposite sides of the first fin and electrically insulated from each other.
13. The method of claim 1, wherein the first fin is disposed in a core region and the second fin is disposed in an input/output region.
14. The method of claim 1, wherein the hard mask is one of SiN, SiO.sub.2, and SiON.
15. The method of claim 1, wherein the gate dielectric layer comprises one of HfO.sub.2, ZrO.sub.2, La.sub.2O.sub.3, Al.sub.2O.sub.3, TiO.sub.2, SrTiO.sub.3, LaAlO.sub.3, Y.sub.2O.sub.3, HfO.sub.xN.sub.y, ZrO.sub.xN.sub.y, La.sub.2O.sub.xN.sub.y, Al.sub.2O.sub.xN.sub.y, TiO.sub.xN.sub.y, SrTiO.sub.xN.sub.y, LaAlO.sub.xN.sub.y, and Y.sub.2O.sub.xN.sub.y, wherein x and y are integer.
16. The method of claim 1, wherein the conductive layer comprises one of W, Ta, TiN, ZrN, HfN, VN, NbN, TaN, WN, TiAlN, TaC, TaMgC, and TaCN.
17. The method of claim 1, wherein the tri-gate FinFET has a source/drain region disposed at a distal end of the first fin and the dual-gate FinFET has a source/drain region disposed at a distal end of the second fin.
18. The method of claim 17, wherein the source/drain region of the tri-gate FinFET comprises SiGe.
19. The method of claim 17, wherein the source/drain region of the dual-gate FinFET comprises SiGe.
20. The method of claim 1, wherein forming the gate dielectric layer comprises: forming an oxide layer having a thickness in a range between about 0.1 nm and about 3 nm with in situ steam-generated (ISSG) or rapid thermal oxidation (RTO) at a temperature in a range between about 700 C. and about 900 C.; submitting the oxide layer to a decoupled plasma nitridation (DPN) process in a nitrogen ambient to form a nitrided oxide layer; and annealing the nitrided oxide layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain embodiments of the invention.
(2)
(3)
(4)
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DETAILED DESCRIPTION OF THE INVENTION
(8) Embodiments of the present invention relate to integrated circuits and the processing for the manufacture of semiconductor devices. More particularly, embodiments of the present invention provide a method and device for providing a dual-gate FinFET and a tri-gate FinFET on the same SOI substrate. Merely by way of example, the invention has been applied to high current drive I/O devices and low leakage core logic devices in integrated circuits. But it would be recognized that the invention has a much broader range of applicability. For example, the invention can be applied to integrated circuits requiring devices having different threshold voltages and performance requirements.
(9) Depending upon the embodiment, the present invention includes various features, which may be used. These features include the following:
(10) 1. Simultaneous fabrication of tri-gate and dual-gate FinFETs on a same substrate;
(11) 2. Fabrication method using conventional process and equipment; and
(12) 3. Method for using tri-gate FinFETs in I/O circuits and dual-gate FinFETs in core logic circuits.
(13) As shown, the above features may be included in one or more of the embodiments to follow. These features are merely examples, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize many variations, modifications, and alternatives.
(14)
(15) The dual-gate FinFET 101 also includes gate oxide regions 131 and 132 disposed on the sides of the silicon fin region. A gate region 150 is disposed on one side of the silicon fin region and is separated from the silicon fin region by gate oxide region 131. A gate region 151 is disposed on an opposing side of the silicon fin region and is separated from the silicon fin region by gate oxide region 132. An end portion of silicon fin region 130 includes a source region 140, and the opposing end portion of the silicon fin region includes a drain region 160. As shown, gate region 150, gate oxide 131 and silicon fin region 130 are associated with an MOS transistor, which also includes a source region 140 and a drain region 160 at its distal ends. Gate 150 is characterized by a width 152 which is associated with a channel length of the transistor. In an embodiment, the channel length is about 5-30 nm. In an embodiment, source region 140 and drain region 160 disposed at the distal ends of the silicon fin region may include silicon germanium (SiGe). In another embodiment, source region 140 and drain region 160 disposed at the distal ends of the silicon fin region may include silicon carbide (SiC).
(16) Referring still to
(17)
(18) In an embodiment of the present invention, a dual-gate FinFET device and a single-gate FinFET device are provided on the same substrate. In an embodiment, an integrated circuit chip includes single-gate FinFETs in I/O circuits and dual-gate FinFETs in core logic circuits. Of course, one of ordinary skill in the art would recognize other variations, modifications, and alternatives.
(19)
(20) A method for fabricating an integrated circuit device according to an embodiment of the present invention may be outlined as follows:
(21) 1. Provide a silicon on insulator (SOI) wafer having a semiconductor layer on an insulator layer and threshold voltage implant;
(22) 2. Form a hard mask overlying the semiconductor layer;
(23) 3. Pattern the hard mask to form a first cap portion and a second cap portion;
(24) 4. Etch the semiconductor layer using the patterned hard mask to form first and second fin regions;
(25) 5. Remove the second cap portion to expose the top surface of the second fin region;
(26) 6. Form a gate dielectric layer on opposite sides of the first silicon fin region and on three sides of the second fin region;
(27) 7. Deposit a conductive layer;
(28) 8. Selectively etch the conductive layer to form a first gate structure for the first fin region and a second gate structure for the second fin region;
(29) 9. Forming source/drain regions at distal ends of the first and second fin regions;
(30) 10. Form an interlayer dielectric layer over the conductive layer;
(31) 11. Planarize the interlayer dielectric layer by chemical mechanical polishing (CMP) using the first cap portion as a polish stop;
(32) 12. Form elevated source/drain regions; and
(33) 12. Perform a backend process.
(34) The above sequence of steps provides a method for fabricating an integrated circuit including a dual gate FinFET and a tri-gate FinFET according to an embodiment of the present invention. As shown, the method uses a combination of steps including a way of fabricating a dual gate FinFET and a single-gate (tri-gate) FinFET on the same SOI substrate. Other alternatives can also be provided where steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein. Further details of the present method can be found throughout the present specification and more particularly below.
(35) To summarize the above steps,
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(39) In process 330, the hard mask is patterned as shown in
(40) In process 340, silicon fin regions are defined. Here, semiconductor layer 430 is etched using the patterned hard mask as an etch mask to form fin regions. In a specific embodiment, conventional reactive ion etching (RIE) process is used to etch semiconductor layer 430.
(41) The method then proceeds to process 350 which removes second hard mask cap portion 620. Second hard mask cap portion 620 can be removed using techniques known in the art such as, for example, ME, wet or dry etching and the like. The silicon fin regions are then annealed in an H.sub.2 ambient at a temperature ranging from about 800 C. to about 1000 C. Silicon fin regions 710, 720 defined in process 340 are used as FET active areas, including source, channel, and drain regions, as will be discussed more in detail below. Of course, there can be other variations, modifications, and alternatives.
(42)
(43) 1. Base oxide grow with in situ steam-generated (ISSG) or rapid thermal oxidation (RTO) at a temperature range of about 700 C. to 900 C. to a thickness of about 0.1-3 nm;
(44) 2. Decoupled Plasma nitridation (DPN) in a nitrogen ambient; and
(45) 3. Post nitridation anneal (PNA).
(46) In an embodiment, the gate dielectric layer includes one of HfO.sub.2, ZrO.sub.2, La.sub.2O.sub.3, Al.sub.2O.sub.3, TiO.sub.2, SrTiO.sub.3, LaAlO.sub.3, Y.sub.2O.sub.3, HfO.sub.xN.sub.y, ZrO.sub.xN.sub.y, La.sub.2O.sub.xN.sub.y, Al.sub.2O.sub.xN.sub.y, TiO.sub.xN.sub.y, SrTiO.sub.xN.sub.y, LaAlO.sub.xN.sub.y, and Y.sub.2O.sub.xN.sub.y, wherein x and y are integer, or other high-K dielectric materials. Of course, there can be other variations, modifications, and alternatives.
(47) In process 365, a conductive layer is deposited over the gate dielectric layer. In an embodiment, the conductive layer includes a metal material comprising one of W, Ta, TiN, ZrN, HfN, VN, NbN, TaN, WN, TiAlN, TaC, TaMgC, and TaCN, and an alloy thereof. The conductive layer can be formed by chemical vapor deposition (CVD), physical vapor deposition (PVD), atomic layer deposition (ALD), vacuum evaporation, and the like. In another embodiment, the conductive layer may include polysilicon. In yet another embodiment, the conductive layer may include conductive refractory metal nitrides. In an embodiment, the conductive layer may have a thickness in a range between about 100 nm to about 500 nm, and preferably in a range between about 40 nm and about 150 nm.
(48) A photolithographic and etch process is performed in process 370 to form gate structures for fin regions. As shown in
(49) In process 375, a source/drain ion implantation is performed to form sources and drains in the fin regions on both distal ends of first and second fin regions 710 and 720. In an embodiment, the source/drain ion implantation may be performed prior to forming gate sidewall spacers.
(50) In process 380, an interlayer dielectric layer 1130 is formed overlying first and second gate structures 1010 and 1020.
(51) Referring still to
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(55) The method also includes implanting impurities to form source regions 1310 and 1330, and drain regions 1320 and 1340 as shown in
(56) In specific embodiments, the method includes process 387 that forms elevated source/drain structures 1410, 1420, 1430, and 1440 as shown in
(57) Alternatively, where FinFETs 1101, 1102 are n-type FinFET, silicon carbide can be epitaxially deposited on source/drain structures 1410, 1420, 1430, and 1440 using in-situ doping techniques. That is, impurities such as phosphorous (P) or arsenic (As) are introduced while the silicon carbide material grows. In an embodiment, a p-type impurity concentration can be in the range from about 110.sup.19 to about 110.sup.20 atoms/cm.sup.3. Of course, there can be other variations, modifications, and alternatives.
(58) In some embodiments of the present invention, the method also includes performing backend processing. As shown in
(59)
(60) A method for operating an integrated circuit device according to an embodiment of the present invention may be outlined as follows:
(61) 1. providing an SOI substrate;
(62) 2. providing a first circuit region in the SOI substrate;
(63) 3. providing a second circuit region in the SOI substrate;
(64) 4. forming a tri-gate FinFET in the first circuit region, the tri-gate FinFET comprising a drain electrode, a source electrode, and a gate electrode;
(65) 5. forming a dual-gate FinFET in the second circuit region, the dual-gate FinFET comprising a drain electrode, a source electrode, and a first gate electrode a second gate electrode;
(66) 6. applying a first bias voltage and second bias voltage to the drain electrode and the source electrode of the tri-gate FinFET, respectively;
(67) 7. receiving a first signal at the gate electrode of the tri-gate FinFET;
(68) 8. applying a third bias voltage and fourth bias voltage to the drain electrode and the source electrode of the dual-gate FinFET, respectively; and
(69) 9. receiving a second signal and a third signal at the first gate electrode and the second gate electrode of the tri-gate FinFET, respectively.
(70) In a specific embodiment, the tri-gate FinFET includes a channel region that is surrounded by the gate electrode on three sides. The dual-gate FinFET includes a channel region sandwiched between the first and second gate electrodes. In some embodiments, the first circuit region is an I/O region. In other embodiments, the second circuit region is a core logic region. In a specific embodiment, the third signal is a dynamic signal generated by another circuit. In some embodiments, the dual-gate FinFET is configured to be operated in a weak inversion region. Of course, there can be other variations, modifications, and alternatives.
(71) The above sequence of processes provides a method for operating an integrated circuit including a dual-gate FinFET and a tri-gate FinFET according to an embodiment of the present invention. As shown, the method uses a combination of steps including a way of operating a dual gate FinFET and a single-gate FinFET on the same SOI substrate. For example, in some embodiments, an integrated circuit chip includes single-gate FinFETs in I/O circuits and dual-gate FinFETs in core logic circuits. Of course, there can be other variations, modifications, and alternatives. Other alternatives can also be provided where steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
(72) It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.