Semiconductor device structure and method for fabricating the same
09711612 ยท 2017-07-18
Assignee
Inventors
Cpc classification
H01L21/76897
ELECTRICITY
H10D64/671
ELECTRICITY
H10D84/0149
ELECTRICITY
International classification
H01L29/49
ELECTRICITY
H01L27/088
ELECTRICITY
H01L27/02
ELECTRICITY
H01L29/66
ELECTRICITY
H01L21/8234
ELECTRICITY
Abstract
A semiconductor device structure and a method for fabricating the same. A method for fabricating semiconductor device structure includes forming gate lines on a semiconductor substrate; forming gate sidewall spacers surrounding the gate lines; forming respective source/drain regions in the semiconductor substrate and on either side of the respective gate lines; forming conductive sidewall spacers surrounding the gate sidewall spacers; and cutting off the gate lines, the gate sidewall spacers and the conductive sidewall spacers at predetermined positions, in which the cut gate lines are electrically isolated gates, and the cut conductive sidewall spacers are electrically isolated lower contacts. The method is applicable to the manufacture of contacts in integrated circuits.
Claims
1. A method for fabricating a semiconductor device structure, comprising: forming gate lines on a semiconductor substrate, the gate lines extending in a gate width direction; forming gate sidewall spacers surrounding the gate lines; forming respective source/drain regions in the semiconductor substrate and on opposite sides of the gate lines in a gate length direction perpendicular to the gate width direction; forming conductive sidewall spacers surrounding the gate sidewall spacers; and cutting off the gate lines, the gate sidewall spacers, and the conductive sidewall spacers at predetermined positions to divide the cut gate lines into gates which are separated from each other in the gate width direction and thus electrically isolated from each other, and to divide the conductive sidewall spacers into lower contacts which are separated from each other in the gate width direction and thus electrically isolated from each other.
2. The method according to claim 1, wherein the step of cutting off the gate lines, the gate sidewall spacers, and the conductive sidewall spacers comprises: the cutting is performed by reactive ion etching or laser cutting.
3. The method according to claim 1, wherein, if there are shallow trench isolations formed in the semiconductor substrate, the positions of cuts are located above the shallow trench isolations.
4. The method according to claim 1, wherein, in the gate width direction, the distance between adjacent electrically isolated gates is 1-10 nm, and the distance between adjacent electrically isolated lower contacts is 1-10 nm.
5. The method according to claim 1, wherein the step of cutting off the gate lines, the gate sidewall spacers, and the conductive sidewall spacers is performed after the conductive sidewall spacers are formed and before the front end of line process for the semiconductor device structure is completed.
6. The method according to claim 1, wherein, after or before the step of cutting off the gate lines, the gate sidewall spacers, and the conductive sidewall spacers, the method further comprises: depositing a dielectric layer; and planarizing the dielectric layer to expose the top of the conductive sidewall spacers or the lower contacts.
7. The method according to claim 1, wherein the lower contacts serve as conductive contacts between outside and the source/drain regions of semiconductor devices.
8. The method according to claim 1, wherein, after the conductive sidewall spacers are formed and before the cutting is performed, the method further comprises: removing the gate lines so as to form openings inside the gate sidewall spacers; and forming replacement gate lines in the openings wherein the cutting off the gate lines comprises cutting the replacement gate lines.
9. The method according to claim 8, wherein, before the replacement gate lines are formed, the method further comprises: forming a gate dielectric layer in the openings.
10. The method according to claim 1, wherein the cutting is performed immediately after the conductive sidewall spacers are follned, so as to form the electrically isolated gates and the electrically isolated lower contacts; and wherein the method further comprises: removing the gates so as to form openings inside the gate sidewall spacers; and forming replacement gates in the openings.
11. The method according to claim 10, wherein, before the replacement gates are formed, the method further comprises: forming a gate dielectric layer in the openings.
12. The method according to claim 6, wherein, after the gate lines, the gate sidewall spacers, and the conductive sidewall spacers are cut off, the method further comprises: forming an inter-layer dielectric layer on the dielectric layer; and forming upper contacts, which are corresponding to the gates and the lower contacts, in the inter-layer dielectric layer, wherein the lower contacts face the upper contacts.
13. The method according to claim 2, wherein, after the conductive sidewall spacers are formed and before the cutting is performed, the method further comprises: removing the gate lines so as to form openings inside the gate sidewall spacers; and forming replacement gate lines in the openings, wherein the cutting off the gate lines comprises cutting off the replacement gate lines.
14. The method according to claim 2, wherein the cutting is performed immediately after the conductive sidewall spacers are formed, so as to form the electrically isolated gates and the electrically isolated lower contacts; and wherein the method further comprises: removing the gates so as to form openings inside the gate sidewall spacers; and forming replacement gates in the openings.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The above and other objects, features, and advantages of the present invention will be more apparent by describing embodiments thereof in detail with reference to the attached drawings, wherein:
(2)
(3)
(4)
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
(5) Hereinafter, the present invention is described with reference to embodiments shown in the attached drawings. However, it is understood that these descriptions are illustrative and not intended to limit the present invention. Further, in the following, well-known structures and techniques are not described to avoid obscuring the concept of the present invention.
(6) In the drawings, various layer-structures according to embodiments of the present invention are shown. However, they are not drawn to scale, and some features may be enlarged while some features may be omitted for purposes of clarity. Moreover, the shapes, sizes, and relative positions of the regions and layers shown in the drawings are also illustrative, and deviations may occur due to manufacture tolerances and technique limitations in practice. Those skilled in the art can also devise regions/layers of other different shapes, sizes, and relative positions as needed.
A First Embodiment
(7) Hereinafter, a first embodiment of the present invention is described with reference to
(8)
(9) In the semiconductor substrate, Shallow Trench Isolations (STIs) 3001 have already been formed, and active regions 3002 are formed in the areas surrounded by STI structures 3001. For of convenience,
(10) Optionally, a gate dielectric layer 3003 (shown in
(11) As shown in
(12) In contrary to the prior art, after the pattern of lines 3004 is formed, a pattern of cuts is not immediately formed using a cut mask. Instead, the gate material layer deposited on the wafer is etched directly using the pattern of lines 3004, so as to form parallel gate lines 3005, as shown in
(13) After the gate lines 3005 are formed, conventional processes may be conducted in order to fabricate semiconductor devices such as transistors. For example, processes such as ion implantation (to perform doping so as to form, for example, sources/drains), sidewall spacer formation, silicidation, and dual stress liner integration may be carried out, which will be described in detail in the following.
(14) Specifically, as shown in
(15) After the sidewall spacers 3006 are formed, it is possible to carry out an etching along the sidewall spacers to remove the gate dielectric layer 3003 located outside the sidewall spacers.
(16) Further, source/drain regions 3007 may be formed beside the respective gates in the substrate 3000 by ion implantation doping. Optionally, before the gate sidewall spacers are formed, source/drain extension regions and Halo regions (not shown) may be formed by tilted ion implantations.
(17) Optionally, the source/drain regions 3007 and the gate lines 3005 may be subjected to silicidation to form a metal silicide layer 3008. The silicide may be formed by: depositing a metal layer, such as W, Co, and Ni, on the entire semiconductor device structure; conducting anneal at a high temperature to make the semiconductor material (Si in this embodiment) react with the metal so as to form the silidice; and finally removing the unreacted metal.
(18) Here, it should be noted that the above processes (such as ion implantation, sidewall spacer formation, and silicidation) for fabricating the semiconductor devices are not directly relevant to the subject matter of the invention, and thus will not be described in detail here. They may be implemented by conventional processes or by future developed processes, and the present invention is not limited thereto.
(19) Next, as shown in
(20)
(21) Subsequently, as shown in
(22)
(23) According to another embodiment of the present invention, it is feasible to form the inter-layer dielectric layer 3013 before cutting the gate lines, the gate sidewall spacers and the conductive sidewall spacers. It is also capable of accomplishing the present invention.
(24) Finally, referring to
(25) On both sides of the gates 3011, there are the source/drain regions 3007 and also the metal silicides 3008 on the source/drain regions 3007.
(26) Preferably, in the direction of gate width, for adjacent devices, the distance between the gates 3011 and the distance between the lower contacts 3012 are 1-10 nm.
(27) Preferably, in the direction of gate width, the respective gates 3011 are isolated from one another by dielectric materials (for example, the inter-layer dielectric layer 3013), and so are the respective lower contacts 3012.
(28) Preferably, according to an embodiment of the present invention, the lower contacts 3012 have the same height the gate stacks and serve as conductive contacts between the source/drain regions of the semiconductor devices and the outside.
(29) To obtain a completed device, it is needed to form upper contacts for the gates and the source/drain regions. In this case, the devices need to be further polished. As shown in
(30) Next, as shown in
A Second Embodiment
(31) The method according to the present invention is also compatible with the replacement gate process. Hereinafter, a second embodiment of the present invention is described with reference to
(32) In the following, emphasis is given to the differences of the second embodiment from the first embodiment and description of the same processes is omitted. Like reference numbers denote like parts throughout the drawings.
(33) As shown in
(34)
(35) Next, as shown in
(36) Optionally, as shown in
(37) Subsequently, a replacement gate process may be conducted. As shown in
(38) Next, as shown in
(39) Alternatively, the replacement gate process may be conducted before forming the inter-layer dielectric layer 3013.
(40) Preferably, a planarization process, for example, CMP, may be performed after the formation of replacement gate lines 3005, so as to make the replacement gate lines 3005 have the same height as the conductive sidewall spacers 3009, which will facilitate subsequent processes.
(41) Then, referring to the process described with reference to
(42) To complete the front end of line (FEOL) process, it is necessary to further fabricate complete contacts. As shown in
(43) Here, it should be noted that, although the replacement gate process is conducted before the cutting process in the above described embodiment, the present invention is not limited to it. It is also feasible to conduct the cutting process before the replacement gate process. For example, the dummy gate lines 3005 may be cut off immediately after the conductive sidewall spacers 3009 are formed so as to form electrically isolated gates 3011 and electrically isolated contacts 3012. Then, the replacement gate process is conducted to form the replacement gates. In a word, the sequences of the steps in various embodiments of the present invention are not limited to those described in the above embodiment.
(44) According to embodiments of the present invention, the cutting of the gate lines, the gate sidewall spacers, and the conductive sidewall spacers may be performed anytime after the conductive sidewall spacers are formed, so as to finally complete the FEOL process for the semiconductor device structure.
(45) The gate sidewall spacers and the conductive sidewall spacers shown in
(46) In the case where the I shaped sidewall spacers are formed, it is possible to not perform CMP polishing, and it is also possible to directly deposit the dielectric layer 3014 without depositing the dielectric layer 3013 and then form upper contacts in the dielectric layer 3014. Such processes are also capable of accomplishing the present invention.
(47) As described above, according to embodiments of the present invention, the pattern of parallel gate lines, after being printed on the substrate (wafer), will not be cut off immediately by using a cut mask as in the prior art. In contrary, the pattern of parallel gate lines is directly used in gate lines etching. Subsequently, processes for forming the semiconductor device structure are performed. Then, by surrounding the gates, more specifically, by surrounding the gate sidewall spacers, contacts to source/drain are formed in a self-aligned manner in a form of sidewall spacer. Finally, the gates and the contacts in a form of sidewall spacer are both cut off by using a cut mask, so as to achieve electrical isolation between devices.
(48) Therefore, according to the present invention, the gate pattern is cut off at a later stage so that the ends of a pair of opposing gates can be closer to each other. Further, in the present invention, the cutting process is conducted to isolate the devices from one another after the formation of gate sidewall spacers and conductive sidewall spacers. Therefore, there will be no sidewall spacer materials remained in the cuts, and there will be no defects, such as voids, as in a conventional process. In to addition, the conductive sidewall spacers (that is, the contacts) for respective devices are entirely cut off by the cuts, and thus it is possible to achieve good electrical isolation between the devices.
(49) Further, unlike the prior art where contacts are formed by etching contact holes and then filling the contact holes with conductive materials, according to embodiments of the invention, the contacts are formed in a form of sidewall spacer, thus eliminating the difficulty in forming contact holes in the prior art. Also, such contacts in a form of sidewall spacer are self-aligned on the source/drain regions, and therefore the process is dramatically simplified. At the same time, it is impossible to form such self-aligned contacts in a form of conductive sidewall spacer according to conventional processes. This is because in conventional processes, the sidewall spacer formation process is conducted after the cuts are formed. In this case, during the formation of sidewall spacers, especially, during the forming of conductive sidewall spacers, conductive materials may enter into the cuts. This will possibly cause the respective conductive sidewall spacers of a pair of opposing gates not to be completely isolated from each other, and thus the corresponding devices will electrically contact with each other.
(50) Furthermore, the present invention is compatible with a replacement gate process. Thus, it is possible to have various options for process.
(51) Moreover, in the present invention, the conductive sidewall spacers (that is, the contacts) and the gate stacks may be made to have the same height by, for example, a planarization process. This facilitates the subsequent processes.
(52) In the above description, details of patterning and etching of the layers are not described. It is understood by those skilled in the art that various measures in the prior art may be utilized to form the layers and regions in desired shapes. Further, to achieve the same feature, those skilled in the art can devise processes not entirely the same as those described above.
(53) The present invention is described above with reference to embodiments thereof. However, these embodiments are provided just for illustrative purposes, rather than limiting the present invention. The scope of the invention is defined by the attached claims as well as equivalents thereof. Those skilled in the art can make various replacements and modifications without departing from the scope of the invention, and the various replacements and modifications all fall into the scope of the invention.