Method of forming shallow trench isolation (STI) structure for suppressing dark current
11705475 · 2023-07-18
Assignee
Inventors
Cpc classification
H01L27/14603
ELECTRICITY
International classification
Abstract
A method of fabricating a target shallow trench isolation (STI) structure between devices in a wafer-level image sensor having a large number of pixels includes etching a trench, the trench having a greater depth and width than a target STI structure and epitaxially growing the substrate material in the trench for a length of time necessary to provide the target depth and width of the isolation structure. An STI structure formed in a semiconductor substrate includes a trench etched in the substrate having a depth and width greater than that of the STI structure, and semiconductor material epitaxially grown in the trench to provide a critical dimension and target depth of the STI structure. An image sensor includes a semiconductor substrate, a photodiode region, a pixel transistor region and an STI structure between the photodiode region and the pixel transistor region.
Claims
1. A method of forming a target shallow trench isolation (STI) structure in a semiconductor substrate, comprising: etching a trench having a bottom and sidewalls in the semiconductor substrate, said trench having a depth (D) deeper than a target depth (TD) of the target STI structure and a width (W) wider than a critical dimension (CD) of the target STI structure; reducing the depth and width of the trench by epitaxially growing a layer of semiconductor material in the trench until the depth equals the target depth and the width equals the critical dimension, wherein the semiconductor substrate and the layer of semiconductor material are formed of the same material; depositing a dielectric material on the layer of semiconductor material in the trench and on the semiconductor substrate; removing a portion of the dielectric material to form an oxide cap having a width greater than the CD and a height h above a substrate surface of the semiconductor substrate; and forming a gate electrode of a transistor on at least a part of the oxide cap and the semiconductor substrate.
2. The method of claim 1, wherein the semiconductor material is epitaxially grown at a temperature between approximately 700 and 750° C.
3. The method of claim 1, wherein the semiconductor substrate and the epitaxially grown layer further comprise doped silicon.
4. The method of claim 1, further comprising growing an oxide layer on the epitaxially grown layer prior to depositing the dielectric material in the trench.
5. The method of claim 1, wherein the step of etching a trench further comprises patterning the semiconductor substrate using masking layers prior to etching.
6. The method of claim 1, further comprising: forming the target STI structure in a top surface of the semiconductor substrate; and forming a photodiode in the semiconductor substrate and at a pixel transistor in the top surface on opposite sides of the target STI structure.
7. The method of claim 1, wherein the semiconductor substrate and the layer of semiconductor material comprise silicon, and the dielectric material comprises an oxide.
8. The method of claim 1, wherein the step of forming the gate electrode comprises forming the gate electrode on a portion of an overlap area between the oxide cap and the substrate surface of the semiconductor substrate.
9. The method of claim 1, further comprising forming a well region having the same conductive type as the semiconductor substrate surrounding the STI structure.
10. The method of claim 9, wherein the well region extends to a depth deeper into the semiconductor substrate than the target depth.
11. The method of claim 1, wherein the step of forming the gate electrode comprises forming the gate electrode on a portion of a first overlap area between the oxide cap of the STI structure and the top surface of the semiconductor substrate and a portion of a second overlap area between the oxide cap of the first second structure and a top surface of the semiconductor substrate.
12. A method of forming a target shallow trench isolation (STI) structure in an image sensor comprising a pixel transistor region disposed in a planar region of a top surface of a semiconductor substrate between two adjacent photodiode regions, the method comprising: forming a first STI structure and a second STI structure parallel to the first STI structure such that i) the pixel transistor region is disposed between the first and second STI structures and ii) the first STI structure and the second STI structure are between the two adjacent photodiode regions, wherein the step of forming each of the first STI structure and the second STI structure comprises: etching a trench having a bottom and sidewalls in the semiconductor substrate, said trench having a depth (D) deeper than a target depth (TD) of the target STI structure and a width (W) wider than a critical dimension (CD) of the target STI structure; and epitaxially growing a layer of semiconductor material in the trench until the depth equals the target depth and the width equals the critical dimension, wherein the semiconductor substrate and the layer of semiconductor material comprises the same material; depositing a dielectric material on the layer of semiconductor material in the trench and on the semiconductor substrate; removing a portion of the dielectric material to form an oxide cap having a width greater than CD and a height h above a substrate surface of the semiconductor substrate; and forming a gate electrode of a pixel transistor on the semiconductor substrate in the pixel transistor region and on the oxide cap of the first STI structure and the oxide cap of the second STI structure.
13. The method of claim 12, wherein the semiconductor substrate and the layer of semiconductor material comprise silicon, and the dielectric material comprises an oxide-based material.
14. The method of claim 12, wherein the pixel transistor further comprises a source electrode and a drain electrode, the gate electrode coupling the source electrode and the drain electrode, and wherein the gate electrode overlaps with both the oxide cap of the first STI structure and the oxide cap of the second STI structure.
15. The method of claim 12, wherein forming the first STI structure and the second STI structure further comprises etching the trench along a channel direction of the pixel transistor.
16. The method of claim 15, further comprising wherein the step of etching the trench along a channel direction of the pixel transistor further comprises etching the trench along the channel direction such that the trench extends across at least two photodiode regions arranged in a row or a column direction.
17. The method of claim 12, further comprising forming the first STI structure and the second STI structures in a well region having the same conductive type as the layer of semiconductor material.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
DETAILED DESCRIPTION OF THE EMBODIMENTS
(11) In embodiments, target shallow trench isolation (STI) structures having a width, typically referred to as a critical dimension (CD) and a target depth (TD) may be formed in a wafer substrate. STI formation in the wafer substrate is performed prior to fabrication of photodiodes, transistors and other devices in the substrate. The CD of STI structures significantly impacts the density of pixels and therefore, the performance of the image sensor.
(12)
(13) Trench 308 is patterned and etched through pad oxide layer 304 and pad nitride layer 306 and into substrate 302 by a process of isotropic dry etching, for example, plasma etching. In embodiments, isotropic dry etching parameters depend on the material of substrate 302 and include pressure, gas composition (e.g., oxygen O.sub.2, fluorine, SF.sub.6, CF.sub.4, CHF.sub.3, C.sub.4F.sub.8), gas generation or injection method, and generator power. When removing material from trench 308, the etching process leaves silicon (Si) dangling bonds 310 on the sidewalls and bottom of the trench. For clarity of illustration, not all Si dangling bonds are labeled with a reference numeral in
(14) In an embodiment, trench 308 is etched to a depth D deeper into substrate 302 than a target depth (TD) of a target STI structure, and to a width W wider than a critical dimension (CD) of the target STI structure. In an embodiment, depth D and target depth (TD) refers to the depth or distance into the substrate 302 from planar surface 305 of substrate 302, for example, a front side surface of substrate 302 or a substrate top surface of substrate 302. After etching, trench 308 may be subjected to surface treatment processes to remove some Si defects and reduce humidity at the trench surface, for example, Siconi™ and hydrogen bake. Siconi™, for example, is a soft dry chemical etching process (e.g. plasma) that may selectively remove oxidized silicon surface defects by exposing the region to be etched to etching agents such as H.sub.2, HF.sub.3 and NH.sub.3. Hydrogen bake is the subsequent surface clearing process used to remove oxide present on the silicon interface. These processes, however, do not remove all Si dangling bonds created by etching.
(15)
(16) Parameters of an epitaxial growth process such as length of time, growth rate and temperature are chosen to grow substrate material on the bottom and sides of trench 308 such that the trench is reduced to the CD and TD of a target STI structure. In an embodiment, the depth of trench 308 is reduced by an amount x that is approximately 50 to 500 angstroms by the epitaxial growth process. Because of the geometry of trench 308, sidewall growth rate is approximately 25-35% of the growth rate of the bottom of the trench. In an embodiment, each sidewall experiences epitaxial growth
(17)
where coefficient α is between approximately 0.25 to 0.35. This results in a range for ax of approximately 15 to 150 angstroms on each sidewall.
(18) Because substrate material is epitaxially grown on the surface of trench 308, Si dangling bonds 310 on the sidewall and bottom of trench 308 as shown in
(19)
(20)
(21) In an embodiment, the width W′ of oxide cap 322 is related to the width W of trench 308 of
(22) Oxide cap 322 prevents exposure of corner 320 of STI structure 318. Although only one corner is indicated in
(23)
(24) Step 402 includes preparing a semiconductor substrate as shown in
(25) Step 404 includes defining a critical dimension (CD) and a target depth (TD) of a target STI structure. In an example of step 404, the CD and the TD of the target STI structure are selected based on a preferred density of pixels and a preferred performance of an image sensor formed in the substrate. Step 406 includes selecting parameters for an epitaxial growth process. In an example of step 406, the selected parameters will provide a growth in bottom thickness of x and a growth in sidewall thickness of
(26)
where coefficient α is between 0.25 to 0.35. This results in a range for ax of approximately 15 to 150 angstroms on each sidewall.
(27) Step 408 includes determining an etching width for trench 308 of
(28) Step 412 includes patterning and etching trench 308. In embodiments, step 412 includes patterning trench 308 prior to an etching process. In an example of step 412, at least one parameter of an etching process is selected to result in a trench 308 having a width W and a depth D as determined in steps 408 and 410. Step 414 includes performing an epitaxial growth process according to the parameters selected in step 406.
(29) Step 416 may include remaining semiconductor fabrication steps including liner oxidation, dielectric fill-in (e.g., oxide fill), chemical mechanical polishing (CMP) and nitride removal as discussed above and depicted in
(30) In an embodiment, method 400 and STI structure 318 described above provide an additional benefit with regard to forming trenches on a substrate using a pad nitride as a mask. Photolithography processes have a lower effective limit in the size of areas that can be effectively masked. This also limits the critical dimension (e.g., target trench width) that can be achieved for a target STI structure. In embodiments, a target STI structure even smaller than the lower photolithography patterning limitation may be formed by etching a trench at the patterning limitation, then epitaxially growing additional substrate material in the trench. This further reduces the space of STI (spacer between photodiode region and pixel transistor region) and increases an area on the substrate for photodiodes, thus larger size of pixel array can be formed achieving higher imaging resolution.
(31) Method 400 provides a shallow trench isolation structure that is free of Si dangling bonds on the bottom and sidewalls of a trench created by plasma etching because silicon is grown epitaxially on these surfaces, curing the Si dangling bonds. In embodiments, any type of substrate may be used, including doped silicon, as doped silicon may also be epitaxially grown to match the substrate. This provides a doped substrate without silicon-surface damage caused by boron implant doping.
(32)
(33) In one example, reset transistor 508, source-follower transistor 510 and row select transistor 512 are N-channel transistors. In such example, source and drain regions of the respective reset transistor 508, source-follower transistor 510 and row select transistor 512 are N-type doped region i.e. doped regions of the second conductive type opposite to the first conductive type of the substrate.
(34) In the illustrated example, referring to
(35) In some embodiments, deep trench isolation structures 522, 524 may also be disposed between adjacent photodiodes 502 and provide electrical isolation between adjacent photodiodes 502.
(36) Source-follower gate 510g of source-follower transistor 510 is located between oxide caps 526 and 528 of STI structures 516 and 518, respectively in the illustrated cross-section view A-A′. As discussed above with reference to
(37) For simplicity, two photodiodes per unit pixel are illustrated in
(38) With the use of the STI structure 516 and 518 in the isolation between photodiodes and pixel transistor region of the image sensor, dark current and white pixel noises may be reduced, and improve imaging performance of the image sensor.
(39) Combinations of Features
(40) Features described above as well as those claimed below may be combined in various ways without departing from the scope hereof. The following enumerated examples illustrate some possible, non-limiting combinations:
(41) (A1) A method of forming a target shallow trench isolation (STI) structure in a semiconductor substrate includes etching a trench having a bottom and sidewalls in the semiconductor substrate, said trench having a depth (D) deeper than a target depth (TD) of the target STI structure and a width (W) wider than a critical dimension (CD) of the target STI structure; and reducing the depth and width of the trench by epitaxially growing a semiconductor material in the trench until the depth reaches the target depth and the width equals the critical dimension.
(42) (A2) In method (A1), the semiconductor material may be epitaxially grown at a temperature between approximately 700 and 750° C.
(43) (A3) In method (A1), the epitaxially grown semiconductor material may be the same as the semiconductor substrate.
(44) (A4) In any of methods (A1)-(A3), the semiconductor substrate and the epitaxially grown semiconductor material may be formed of silicon.
(45) (A5) In method (A4), the epitaxially grown semiconductor material is doped silicon.
(46) (A6) Any of methods (A1)-(A5) may further include oxidizing the semiconductor substrate to form an oxide layer on a surface of the semiconductor substrate.
(47) (A7) Method (A6) may further include filling the trench with an oxide.
(48) (A8) Method (A7) may further include forming an oxide cap having a width greater than CD and a height h above a substrate top surface.
(49) (A9) In any of methods (A1)-(A8) D−TD may be between approximately 50 and 500 angstroms.
(50) (A10) In any of methods (A1)-(A9), (W−CD)/2 may be between approximately 15 and 150 angstroms.
(51) (A11) In any of methods (A1)-(A10), when the substrate may have a top surface, the method may further include forming the target STI structure in the top surface and forming a photodiode and at least one pixel transistor in the top surface on opposite sides of the target STI structure.
(52) (B1) A shallow trench isolation (STI) structure having a target depth TD and a critical dimension CD includes a semiconductor substrate having a substrate top surface forming a trench extending into the semiconductor substrate and having a trench depth D relative to a planar region of the substrate top surface surrounding the trench such that D is greater than TD and a trench width W at the substrate top surface such that W is greater than CD; and a semiconductor material epitaxially grown in the trench to provide the STI structure having a target depth equal to TD and a critical dimension equal to CD.
(53) (B2) In structure (B1), the epitaxially grown semiconductor material is the same as the semiconductor substrate.
(54) (B3) In structures (B2), the semiconductor substrate and the epitaxially grown semiconductor material may be formed of silicon.
(55) (B4) In structure (B3), the epitaxially grown semiconductor material is doped silicon.
(56) (B5) Any of structures (B1)-(B4) may further include an oxide filling said trench.
(57) (B6) Any of structures (B1)-(B5) may further include an oxide cap having a width greater than CD and a height h above a substrate top surface.
(58) (B7) In any of structures (B1)-(B6), D−TD may be between approximately 50 and 500 angstroms.
(59) (B8) In any of structures (B1)-(B7), (W−CD)/2 may be between approximately 15 and 150 angstroms.
(60) (B9) In any of the structures (B1)-(B8), the STI structure may be disposed on a wafer between at least one photodiode and at least one pixel transistor formed on the wafer.
(61) (C1) An image sensor includes a semiconductor substrate; a photodiode region have one or more photodiodes formed in a planar region of a substrate top surface of the semiconductor substrate; a pixel transistor region including one or more pixel transistors formed in the planar region of the substrate top surface; and an STI structure according to any of embodiments (B1)-(B9) formed between the photodiode region and the pixel transistor region according to any of the method embodiments of (A1)-(A11).
(62) Changes may be made in the above methods and systems without departing from the scope hereof. It should thus be noted that the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. Herein, and unless otherwise indicated: (a) the adjective “exemplary” means serving as an example, instance, or illustration, and (b) the phrase “in embodiments” is equivalent to the phrase “in certain embodiments,” and does not refer to all embodiments. The following claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the present method and system, which, as a matter of language, might be said to fall therebetween.