Method to thin down indium phosphide layer

Abstract

The disclosed subject matter provides a Fin-FET with a thinned-down InP layer and thinning-down method thereof. In a Fin-FET, the fin structure is made of InGaAs and an InP layer is formed to cover the fin structure. The InP layer is obtained from an initial InP layer formed on the fin structure through a thinning down process including converting a surface portion of the InP layer into a Phosphorus-rich layer and removing the Phosphorus-rich layer. The thickness of the ultimately-formed InP layer is less than or equal to 1 nm. According to the disclosed method, the InP layer in the Fin-FET may be easily thinned down, and during the thinning-down process, contamination may be avoided.

Claims

1. A method for thinning down an InP layer formed on a fin structure, comprising: providing a fin structure, wherein the fin structure is made of InGaAs; forming an InP layer to cover the fin structure; converting a surface portion of the InP layer into a Phosphorus-rich layer; and removing the Phosphorus-rich layer, wherein a remaining portion of the InP layer becomes a thinned-down InP layer.

2. The method for thinning down the InP layer according to claim 1, after removing the Phosphorus-rich layer, further including: forming a dielectric layer to cover the thinned-down InP layer; and forming a gate electrode on the dielectric layer.

3. The method for thinning down the InP layer according to claim 1, wherein the Phosphorus-rich layer is formed by a dry etching process using an etch gas including Cl.sub.2 and Ar.

4. The method for thinning down the InP layer according to claim 3, wherein the dry etching process to form the Phosphorus-rich layer is a chemical dry etching process.

5. The method for thinning down the InP layer according to claim 4, wherein process parameters of the chemical dry etching process to form the Phosphorus-rich layer include: a process temperature in a range of 10 to 200 C.; a process pressure in a range of 5 to 500 mTorr; a power in a range of 100 to 1000 W; a flow rate of Cl.sub.2 in a range of 10 to 200 sccm; and a flow rate of Ar in a range of 10 to 500 sccm.

6. The method for thinning down the InP layer according to claim 1, wherein the Phosphorus-rich layer is removed by a dry etching process using HBr as an etch gas.

7. The method for thinning down the InP layer according to claim 6, wherein the dry etching process to remove the Phosphorus-rich layer is a chemical dry etching process.

8. The method for thinning down the InP layer according to claim 7, wherein process parameters of the chemical dry etching process to remove the Phosphorus-rich layer include: a process pressure in a range of 5 to 500 mTorr; a power in a range of 100 to 1000 W; and a flow rate of HBr in a range of 50 to 500 sccm.

9. The method for thinning down the InP layer according to claim 1, wherein the Phosphorus-rich layer is removed by a method including: performing an oxygen treatment process on the Phosphorus-rich layer; and removing the oxygen-treated Phosphorus-rich layer by a dry etching process using H.sub.2 as an etch gas.

10. The method for thinning down the InP layer according to claim 9, wherein the oxygen treatment process is a chemical dry etching process.

11. The method for thinning down the InP layer according to claim 10, wherein process parameters of the chemical dry etching process to treat the Phosphorus-rich layer with oxygen include: a process pressure in a range of 5 to 500 mTorr; a power in a range of 100 to 1000 W; and a flow rate of O.sub.2 in a range of 10 to 200 sccm.

12. The method for thinning down the InP layer according to claim 9, wherein the dry etching process to remove the oxygen-treated Phosphorus-rich layer is a chemical dry etching process.

13. The method for thinning down the InP layer according to claim 12, wherein process parameters of the chemical dry etching process to remove the oxygen-treated Phosphorus-rich layer include: a process pressure in a range of 5 to 500 mTorr; a power in a range of 100 to 1000 W; and a flow rate of H.sub.2 in a range of 50 to 500 sccm.

14. The method for thinning down the InP layer according to claim 1, wherein the process to form a Phosphorus-rich layer and the process to remove the formed Phosphorus-rich layer are repeated at least 2 times.

15. The method for thinning down the InP layer according to claim 14, wherein after performing each process to form a Phosphorus-rich layer, a thickness of the Phosphorus-rich layer is less than 1 nm.

16. The method for thinning down the InP layer according to claim 1, wherein a thickness of the ultimately thinned-down InP layer is smaller than or equal to 1 nm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The following drawings are merely examples for illustrative purposes according to various disclosed embodiments and are not intended to limit the scope of the present disclosure.

(2) FIG. 1 illustrates a flowchart of an exemplary fabrication process consistent with disclosed embodiments; and

(3) FIGS. 2-7 illustrate schematic views of semiconductor structures corresponding to certain stages of another exemplary fabrication method consistent with disclosed embodiments.

DETAILED DESCRIPTION

(4) Reference will now be made in detail to exemplary embodiments of the invention, which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

(5) As described in above background section, existing methods to thin down an InP layer formed on an InGaAs fin structure usually includes performing an ashing process on the InP layer using oxygen gas and then performing a wet etching process at room temperature to remove the ashed portion of the InP layer. During the wet etching process, an etch solution mixed by diluted sulfuric acid and water at a 1:1 ratio may be used. However, the wet etching process may introduce some contaminants, which may affect the performance of the device. In addition, as the device may need to be alternatively handled in dry and wet operation environments, the fabrication process may be more complicated, the processing time may be longer, and the probability of getting the device contaminated may also increase.

(6) Accordingly, the present disclosure provides an improved method to thin down the InP layer formed on the InGaAs fin structure. FIG. 1 shows a flowchart of an exemplary fabrication process consistent with various disclosed embodiments. FIGS. 2-7 show schematic views of the structures corresponding to certain stages of the exemplary fabrication method illustrated in FIG. 1.

(7) Referring to FIG. 1, at the beginning of the fabrication process, a plurality of fin structures formed on a semiconductor substrate is provided (S101). FIG. 2 shows a schematic cross-section view of the semiconductor substrate, the active region, and the two isolation structures.

(8) Referring to FIG. 2, a semiconductor substrate 200 is provided. A plurality of fin structures 201 made of InGaAs is formed on the semiconductor substrate 200.

(9) The semiconductor substrate 200 may have a single-layer structure or a multiple-layer structure. When the semiconductor substrate 200 has a single-layer structure, the semiconductor substrate 200 may be made of one of Si, Ge, SiGe, SiC, GaN, etc. When the semiconductor substrate 200 has a multiple-layer structure, the semiconductor substrate 200 may include a semiconductor layer (not shown) and one or more interlayer dielectric layers (not shown) formed on the surface of the semiconductor layer.

(10) The plurality of fin structures 201 may be made of InGaAs. InGaAs is a III-V group compound and has characteristics of low energy consumption. Therefore, the carrier mobility in the fin structures 201 may be improved.

(11) The cross-section of each fin structure along a direction perpendicular to the elongation direction of the fin structure may be a rectangle, a trapezoid, or a combination of rectangle and trapezoid. In one embodiment, the cross-section of each fin structure along a direction perpendicular to the elongation direction of the fin structure is a trapezoid. The plurality of fin structures 201 may be fabricated on the semiconductor substrate 200 by any appropriate method known in the field.

(12) Further, returning to FIG. 1, an InP layer may be formed on the fin structures (S103). FIG. 3 shows a schematic cross-section view of the corresponding semiconductor structure.

(13) Referring to FIG. 3, an InP layer 203 may be formed to cove the fin structures 201. The InP layer 203 may be formed by any appropriate method know in the field and no specific restriction is required. For example, the InP layer 203 may be formed by a physical vapor deposition method such as plasma sputtering, molecular beam epitaxy (MBE), e-beam evaporation, pulsed-laser deposition, magnetron sputtering, etc. In addition, in certain embodiments, a metal organic chemical vapor deposition (MOCVD) method may also be adopted to form the InP layer 203. Due to the limitation of the processing conditions, the thickness of the InP layer formed by above methods may be at least several tens of nanometers.

(14) In one embodiment, the InP layer is formed by an MOCVD method and the thickness of the InP layer 203 is 30 nm. In a subsequent process, the thickness of the InP layer may be reduced in order to reach a relatively thin InP layer.

(15) Further, returning to FIG. 1, a surface portion of the InP layer may be converted into a Phosphorus-rich layer (S105). FIG. 4 shows a schematic cross-section view of the corresponding semiconductor structure.

(16) Referring to FIG. 4, a surface portion of the InP layer 203 (referring to FIG. 3) formed on the fin structure 201 may be converted into a Phosphorus-rich layer 205. The Phosphorus-rich layer 205 may be formed by a dry etching process. The dry etching process may use an etch gas including CI.sub.2 and Ar. During the dry etching process, a portion of the indium atoms near the surface of the InP layer 203 (referring to FIG. 3) may be removed. Thus, with a major ingredient of Phosphorus, the remained surface portion becomes the Phosphorus-rich layer 205. The thickness of the Phosphorus-rich layer 205 after the dry etching process may be less than 1 nm. The portion of the InP layer 203 (referring to FIG. 3) not affected by the dry etching process, i.e., the ultimately-formed InP layer after the thinning-down process, is labeled as 207.

(17) In one embodiment, the dry etching process to convert the surface portion of the InP layer 203 may be a chemical dry etching process. The process parameters for the chemical dry etching process may include a process temperature in a range of 10 to 200 C., a process pressure in a range of 5 to 500 mTorr, a power in a range of 100 to 1000 W, a flow rate of Cl.sub.2 in a range of 10 to 200 sccm, and a flow rate of Ar in a range of 10 to 500 sccm. The process conditions for such a chemical dry etching process may be mild so that damages to the surface of the unconverted InP layer, i.e., the ultimately-formed InP layer 207, during the thinning-down process may be reduced, which further ensures that the performance of the Fin-FET is not affected.

(18) Further, returning to FIG. 1, the Phosphorus-rich layer may be removed (S107). FIG. 5 shows a schematic cross-section view of the corresponding semiconductor structure.

(19) Referring to FIG. 5, the Phosphorus-rich layer 205 is removed. The Phosphorus-rich layer 205 may be removed by a dry etching process. The dry etching process may use HBr as an etch gas. During the dry etching process, the Phosphorus-rich layer 205 is gradually removed and only the unconverted portion of the InP layer, i.e., the ultimately-formed InP layer 207, remains. As such, the goal to thin down the InP layer 203 may be reached.

(20) In one embodiment, the dry etching process to remove the Phosphorus-rich layer 205 is a chemical dry etching process. The process parameters for the chemical dry etching process may include a process pressure in a range of 5 to 500 mTorr, a power in a range of 100 to 1000 W, and a flow rate of HBr in a range of 50 to 500 sccm. The process conditions for such a chemical dry etching process may be mild so that damages to the surface of the unconverted InP layer, i.e. the ultimately-formed InP layer 207, during the thinning-down process may be reduced, which further ensures that the performance of the Fin-FET is not affected.

(21) In other embodiments, the chemical dry etching process to form the Phosphorus-rich layer 205 using CI.sub.2 and Ar as an etch gas and the subsequent chemical dry etching process to remove the Phosphorus-rich layer 205 using HBr as an etch gas may be performed multiple times in order to obtain a desired thickness for the ultimately-formed InP layer 207. During the dry etching process to form the Phosphorus-rich layer 205, the process temperature and the flow rate of Ar may directly affect the etching rate. Specifically, with a higher process temperature, the etching rate may be higher; while with a higher flow rate of Ar, the etching rate may also be higher. In addition, during each HBr etching process, the thickness of the removed Phosphorus-rich layer 205 may be less than 1 nm.

(22) The thickness if the ultimately-formed Inp layer 207 after being thinned down may not be greater than 1 nm. When the thickness of the Inp layer is equal to or less than 1 nm, the heat dissipation effect may be desired while the required drive voltage is also relatively small.

(23) The fabrication method may further include forming a dielectric layer on the surface of each fin structure and a gate electrode on the dielectric layer to complete Fin-FET structures. FIG. 6 shows a schematic cross-section view of the corresponding semiconductor structure.

(24) Referring to FIG. 6, a gate structure may be formed on the thinned-down Inp layer 207. The gate structure may across the whole length of the corresponding fin structure 201. Specifically, the gate structure includes a dielectric layer 209 formed on the thinned-down Inp layer 207 and a gate electrode 211 formed on the dielectric layer 209. The gate structures may be formed by any appropriate method know in the field.

(25) In certain other embodiments, the Phosphorus-rich layer 205 may be removed by a method different from the HBr chemical dry etching process described above. For example, the Phosphorus-rich layer 205 may be removed by an oxygen treatment process followed by a H.sub.2 dry etching process. Specifically, the Phosphorus-rich layer 205 may be treated by O.sub.2 and then the O.sub.2-treated Phosphorus-rich layer may be removed by a H.sub.2 dry etching process. FIG. 7 shows a schematic cross-section view of the corresponding semiconductor structure after the oxygen treatment process.

(26) Referring to FIG. 7, an O.sub.2-treated Phosphorus-rich layer 205 is formed by using O.sub.2 to treat the Phosphorus-rich layer 205. A hydrogen dry etching process is then preformed to remove the O.sub.2-treated Phosphorus-rich layer 205 and obtain a thinned-down InP layer. As such, the goal to thin down the InP layer 203 may be reached.

(27) The oxygen treatment and the hydrogen dry etching are both chemical dry etching process. The process parameters for the oxygen treatment process may include a process pressure in a range of 5 to 500 mTorr, a power in a range of 100 to 1000 W, and a flow rate of O.sub.2 in a range of 10 to 200 sccm. The process parameters for the chemical dry etching process to remove the O.sub.2-treated Phosphorus-rich layer 205 may include a process pressure in a range of 5 to 500 mTorr, a power in a range of 100 to 1000 W, and a flow rate of H.sub.2 in a range of 50 to 500 sccm. The process conditions for chemical dry etching processes may be mild so that damages to the surface of the unconverted InP layer, i.e. the ultimately-formed InP layer 207, during the thinning-down process may be reduced, which further ensures that the performance of the Fin-FET is not affected.

(28) In certain other embodiments, the process to form a Phosphorus-rich layer and the subsequent process to remove the Phosphorus-rich layer may need to be repeated n times with n no less than 2. When Ar is used to form a Phosphorus-rich layer, the process temperature and the flow rate of Ar may directly affect the etching rate. Specifically, with a higher process temperature, the etching rate may be higher; while with a higher flow rate of Ar, the etching rate may also be higher. In addition, during each oxygen treatment process and the following H.sub.2 dry etching process, the thickness of the removed Phosphorus-rich layer 205 may be less than 1 nm.

(29) Therefore, the etched thickness may be controlled by adjusting the process temperature, the Ar flow rate, and the etching time. When the Phosphorus-rich layer formed each time is thinner, the process to form and remove Phosphorus-rich layer may need to be repeated more times; in the meantime, the thickness of the ultimately thinned-down InP layer may also be more precisely controlled and damage to the surface of the thinned-down InP layer may also be reduced. In one embodiment, the thickness of the Phosphorus-rich layer formed each time is smaller than 1 nm.

(30) According to the disclosed methods, a surface portion of the InP layer formed on the fin structure may be converted into a Phosphorus-rich layer in order to reduce the thickness of the InP layer. The Phosphorus-rich layer may be easily removed, and during the removal process, contaminations may not be induced.

(31) Further, the Phosphorus-rich layer may be removed by a dry etching process. During the etching process, contaminations may be less. In addition, using a dry etching process to remove the Phosphorus-rich layer may also reduce alternation of dry and wet operation environments for the device. Therefore, the processing time may be reduced, and the probability of getting the device contaminated may also decrease.

(32) Further, according to the disclosed methods, the dry etching process to form or remove the Phosphorus-rich layer is a chemical dry etching process. For such a chemical dry etching process, the process conditions may be mild so that damages to the devices may be reduced.

(33) Further, according to the disclosed methods, the process to form Phosphorus-rich layer and the process to remove Phosphorus-rich layer may be repeated multiple times. Therefore, controllability of process engineering may be increased, which further ensures the performance of the device.

(34) The above detailed descriptions only illustrate certain exemplary embodiments of the present invention, and are not intended to limit the scope of the present invention. Those skilled in the art can understand the specification as whole and technical features in the various embodiments can be combined into other embodiments understandable to those persons of ordinary skill in the art. Any equivalent or modification thereof, without departing from the spirit and principle of the present invention, falls within the true scope of the present invention.