FinFET device and method
09679992 ยท 2017-06-13
Assignee
Inventors
Cpc classification
H10D30/797
ELECTRICITY
H10D30/791
ELECTRICITY
H10D30/0243
ELECTRICITY
H10D30/6211
ELECTRICITY
H10D64/017
ELECTRICITY
International classification
H01L29/66
ELECTRICITY
H01L29/36
ELECTRICITY
H01L29/10
ELECTRICITY
Abstract
A fin field effect transistor (FinFET) and a method of forming the same are introduced. In an embodiment, trenches are formed in a substrate, wherein a region between adjacent trenches defines a fin. A dielectric material is formed in the trenches. A part of the substrate is doped and a region of high dopant concentration and a region of low dopant concentration are formed. Gate stacks are formed, portions of the fins are removed and source/drain regions are epitaxially grown in the regions of high/low dopant concentration. Contacts are formed to provide electrical contacts to source/gate/drain regions.
Claims
1. A method of fabricating a semiconductor device, the method comprising: forming a fin extending from a substrate, the fin having a first region having dopants of a first conductivity type at a first concentration and a second region having dopants of the first conductivity type at a second concentration; after forming the fin, forming a gate stack over the fin, a first lateral edge of the fin being over the first region and a second lateral edge of the fin being over the second region; and forming source/drain regions on opposing sides of the gate stack such that a first source/drain region is in the first region and a second source/drain region is in the second region.
2. The method of claim 1, further comprising forming a semiconductor material in the first region and the second region.
3. The method of claim 2, wherein forming the semiconductor material comprises: recessing portions of the fin; and epitaxially growing the semiconductor material over recessed portions of the fin.
4. The method of claim 2, wherein the semiconductor material is a stress-inducing material.
5. The method of claim 1, wherein the first concentration is between about 1E17 cm .sup.3 and about 5E18 cm.sup.3.
6. The method of claim 5, wherein the second concentration is between about 1% and about 50% of the first concentration.
7. The method of claim 1, further comprising forming a dummy gate over the first region.
8. A method of fabricating a semiconductor device, the method comprising: forming a fin extending from a substrate, the substrate being of a first conductivity type; forming a first region of the first conductivity type in the fin, the first region being adjacent a second region of the fin, the first region having a first concentration of dopants of the first conductivity type, the second region having a second concentration of dopants of the first conductivity type, the first concentration being greater than the second concentration; and after forming the first region, forming a gate stack over the fin, the gate stack having a first lateral edge over the first region and a second lateral edge over the second region.
9. The method of claim 8, wherein forming the fin is performed prior to forming the first region.
10. The method of claim 8, wherein the gate stack overlies an interface between the first region and the second region.
11. The method of claim 10, further comprising forming a first source/drain region and a second source/drain region on opposing sides of the gate stack, wherein a distance between the first source/drain region and the interface between the first region and the second region is larger than a distance between the second source/drain region and the interface between the first region and the second region.
12. The method of claim 8, wherein the first concentration is between about 1E17 cm .sup.3 and about 5E18 cm.sup.3.
13. The method of claim 8, wherein the second concentration is between about 1% and about 50% of the first concentration.
14. A method of fabricating a semiconductor device, the method comprising: forming a channel region in a fin, the channel region having a first portion having a first dopant concentration of a first conductivity type and a second portion having a second dopant concentration of the first conductivity type, the first dopant concentration being greater than the second dopant concentration; forming a source region on a first side of the channel region, the source region having a second conductivity type; forming a drain region on a second side of the channel region opposite the first side, the drain region having the second conductivity type; and forming a gate stack over the channel region, the gate stack extending over a junction between the first portion and the second portion.
15. The method of claim 14, wherein forming the source region is performed after forming the channel region.
16. The method of claim 14, wherein forming the gate stack is performed after forming the channel region.
17. The method of claim 14, wherein forming the channel region comprises: patterning a substrate to form the fin, the substrate having the first dopant concentration of the first conductivity type; masking a protected region of the substrate; and doping an unprotected region of the substrate, after the doping, the unprotected region forming the first portion and the protected region forming the second portion.
18. The method of claim 17, wherein patterning the substrate is performed prior to masking the protected region.
19. The method of claim 18, wherein doping the unprotected region is performed by implanting.
20. The method of claim 18, wherein masking the protected region comprises: forming a dielectric material over the fin; and planarizing the dielectric material to expose an upper surface of the fin.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
(2)
(3)
(4)
(5) Corresponding numerals and symbols in the different figures generally refer to corresponding parts unless otherwise indicated. The figures are drawn to clearly illustrate the relevant aspects of the embodiments and are not necessarily drawn to scale.
DETAILED DESCRIPTION
(6) The making and using of the present embodiments are discussed in detail below. It should be appreciated, however, that the present disclosure provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative of specific ways to make and use the disclosed subject matter, and do not limit the scope of the different embodiments.
(7) The present disclosure is presented in terms of forming a fin field effect transistor (FinFET) with high breakdown voltage characteristics. As will be described in detail below, a substrate and fins are inhomogeneously doped to form regions of high and low dopant concentrations. Sources and drains are subsequently formed in the region of high dopant concentration and the region of low dopant concentration, respectively. By suitably adjusting device parameters, performance enhancements are achieved, such as increase of a breakdown voltage while maintaining a high drain current.
(8)
(9) In an embodiment, the substrate 101 may comprise a p-doped silicon, doped using, for example, boron or other suitable acceptor dopants to form a body of an NMOS FinFET device. In an embodiment, the substrate 101 has a dopant concentration of between about 1E15 cm.sup.3 and about 1E17 cm.sup.3. This disclosure is presented in terms of forming an NMOS device. In other embodiments, dopants may be selected to form a PMOS device.
(10) The substrate 101 may be patterned to form the fins 103 using, for example, photolithography techniques. Generally, a photoresist material (not shown) is deposited, irradiated (exposed), and developed to remove a portion of the photoresist material. The remaining photoresist material protects the underlying material from subsequent processing steps, such as etching. In this example, the photoresist material is used to form a patterned mask (not shown) to protect sections of the substrate 101 while etching trenches in the substrate, thereby defining the fins 103. Subsequently, the photoresist material is removed using, for example, an ashing process in combination with a wet clean process.
(11) In some embodiments, it may be desirable to use an additional mask layer. During the etching process to pattern the substrate 101, portions of the patterned photoresist material may also be removed. In some instances, the entire photoresist material may be removed prior to the completion of the etching process to from the fins 103. In these situations, the additional mask, such as a hard mask, may be used. For example, a hard mask layer (not shown) may comprise an oxide layer (not shown) and an overlying nitride layer (not shown), and may be formed over the substrate 101 to further aid in the patterning process of the substrate 101. The oxide layer may be a thin film comprising silicon oxide formed, for example, using a thermal oxidation process. In an embodiment, the nitride layer is formed of silicon nitride, for example, using low-pressure chemical vapor deposition (LPCVD), plasma enhanced chemical vapor deposition (PECVD), or similar.
(12) The substrate 101 is etched to remove exposed portions of the substrate 101 to form trenches in the substrate 101, wherein portions of the substrate 101 between adjacent trenches form the fins 103. The substrate 101 is etched, for example, by an anisotropic wet etch process or an anisotropic dry etch process. In an embodiment, the anisotropic wet etch may be performed on the substrate 101 comprising silicon using potassium hydroxide (KOH), ethylenediamine pyrocatechol (EDP), tetramethylammonium hydroxide (TMAH), or similar. The anisotropic dry etch process may include physical dry etching, chemical dry etching, reactive ion etching, or similar. In an embodiment, the ions that are used in chemical dry etching of silicon are tetrafluoromethane (CF.sub.4), sulfur hexafluoride (SF.sub.6), nitrogen trifluoride (NF.sub.3), chlorine gas (Cl.sub.2), or fluorine (F.sub.2). The typical reactive ion etching gasses for silicon are CF.sub.4, SF.sub.6 and BCl.sub.2+Cl.sub.2. In some embodiments, when viewed from above, the trenches may be strips parallel to each other, and closely spaced with respect to each other. In some embodiments, the trenches may be continuous and surrounding the fins 103. In other embodiments, the fins 103 may be formed using a suitable multiple pattering method such as, for example, the sidewall image transfer (SIT) process. In an embodiment, the fins 103 may have a height of between about 20 nm to about 50 nm.
(13) In some embodiments, the trenches between the adjacent fins 103 in the substrate 101 are filled with a dielectric material to form the STI layer 105. The STI layer 105 may comprise silicon oxide, silicon nitride, fluoride-doped silicate glass (FSG), or a low-K dielectric material, may also be used. In some embodiments, the STI layer 105 may be formed using a high-density-plasma (HDP) CVD process, using silane (SiH.sub.4) and oxygen (O.sub.2) as reacting precursors. In other embodiments, the STI layer 105 may be formed using a sub-atmospheric CVD (SACVD) process or high aspect-ratio process (HARP), wherein process gases may comprise tetraethylorthosilicate (TEOS) and ozone (O.sub.3). In yet other embodiments, the STI layer 105 may be formed using a spin-on-dielectric (SOD) process, such as hydrogen silsesquioxane (HSQ) or methyl silsesquioxane (MSQ). Other processes and materials may be used. A chemical mechanical planarization (CMP) may be performed to remove excess portion of the dielectric material forming the STI layer 105 as illustrated in
(14) In reference to
(15) In an embodiment, the protected region 205 has a first width W.sub.1 and a first length L.sub.1 (as viewed from above), as illustrated in
(16) In an embodiment, the substrate 101 may comprise a p-doped silicon, which is further doped in the unprotected region 203, thereby forming a p.sup.+-well 207 in the unprotected region 203 of the substrate 101 and a p.sup.-well 209 in the protected region 205 of the substrate 101. The dopant concentration of the p.sup.+-well 207 is different from the dopant concentration of the substrate 101 and the p.sup.-well 209, and the dopant concentration of the p.sup.-well 209 may be between about 1% and about 50% of the dopant concentration of the p.sup.+-well 207. In an embodiment, the p.sup.+-well 207 has the dopant concentration of between about 1E17 cm.sup.3 and about 5E18 cm.sup.3, and the p.sup.-well 209 has the dopant concentration of between about 1E15 cm.sup.3 and about 2.5E18 cm.sup.3.
(17) In another embodiment, the p.sup.+-well 207 may be formed prior to forming the trenches and fins 103. For example, the substrate 101 may be masked and an implant process, such as that discussed above, may be performed to create the p.sup.+-well 207. Once the p.sup.+-well 207 is formed, the substrate 101 may be masked and patterned to form the trenches and the STI layer 105 may be formed.
(18) Referring now to
(19)
(20)
(21)
(22) In an embodiment, portions of the fins 103 are removed and replaced with the stress-inducing material 505. For example, the STI layer 105 may act as a hard mask for a selective etch process to recess exposed portions of the fins 103. In some embodiments, the etching process may be performed using a chemical selected from Cl.sub.2, HBr, NF.sub.3, CF.sub.4, and SF.sub.6 as an etching gas. In some embodiments, the fins 103 in the source region 501 and the drain region 503 are recessed to a depth of about 30 nm to about 60 nm below an upper surface of the fins 103 in the channel region. In some embodiments, portions of the STI layer 105 may also be recessed to form, for example, a common source/drain trench. A suitable semiconductor material is epitaxially grown in recesses to form the source regions 501 and the drain regions 503 as illustrated in
(23) The source regions 501 and the drain regions 503 may be in-situ doped during the epitaxial process and/or one or more subsequent doping process, e.g., an implant, may be performed. For example, epitaxially grown silicon source/drain regions may be doped with n-type dopants, e.g., phosphorous or the like, to form an NMOS device, or p-type dopants, e.g., boron or the like, to form a PMOS device. Multiple doping processes may be utilized to create a desired doping profile, including, for example, lightly-doped drain (LDD) regions and the like. In an embodiment, the source regions 501 and the drain regions 503 may have a dopant concentration of between about 5E18 cm.sup.3 and about 1E20 cm.sup.3.
(24) Further manufacturing steps may be performed on the semiconductor device 100. For example, an interlayer dielectric (ILD) layer (discussed below in reference to
(25)
(26) The contacts 603 are formed in the ILD layer 601 to provide electrical contacts to the source regions 501, the drain regions 503, and the gate stack 405. The ILD layer 601 may be patterned using photolithography techniques to form trenches and vias. The contacts 603 are formed by depositing a suitable material in the trenches and the vias of the ILD layer 601 using various deposition and plating methods, or similar. In addition, the contacts 603 may include one or more barrier/adhesion layers (not shown) to protect the ILD layer 601 from diffusion and metallic poisoning. The barrier layer may comprise titanium, titanium nitride, tantalum, tantalum nitride, or other alternatives. The barrier layer may be formed using PVD, CVD, or the like.
(27) The material of the contacts 603 may comprise copper, a copper alloy, silver, gold, tungsten, tantalum, aluminum, and the like. In an embodiment, the steps for forming the barrier layer and the contacts 603 may include blanket forming barrier layer, depositing a thin seed layer of a conductive material, and filling the trenches and the vias in the ILD layer 601 with the conductive material, for example, by plating. A CMP is then performed to remove excess barrier layer and the conductive material.
(28) In reference to
(29) The first dummy gate stack 401 has a second width W.sub.2 of between about 0.01 m and about 1 m, and the second dummy gate stack 403 has a third width W.sub.3 of between about 0.01 m and about 1 m. In an embodiment, the second width W.sub.2 and the third width W.sub.3 may equal to each other. In another embodiment, the second width W.sub.2 and the third width W.sub.3 may be different from each other. A third distance X.sub.3 between a right edge of the first dummy gate stack 401 and a left edge of the gate stack 405 is between about 0.05 m and about 0.5 m. A fourth distance X.sub.4 between a right edge of the gate stack 405 and a left edge of the second dummy gate stack 403 is between about 0.05 m and about 0.5 m. In an embodiment, the third distance X.sub.3 and the fourth distance X.sub.4 may equal to each other. In another embodiment, the third distance X.sub.3 and the fourth distance X.sub.4 may be different from each other.
(30) These widths and relative distances may be adjusted for a particular design or application. For example, in an embodiment with the first distance X.sub.1 greater than the second distance X.sub.2, the semiconductor device 100 may display high breakdown voltage characteristics, while having low drain current characteristics. In another embodiment with the first distance X.sub.1 less than the second distance X.sub.2, the semiconductor device 100 may display low breakdown voltage characteristics, while having high drain current characteristics. The first distance X.sub.1 and the second distance X.sub.2 can be chosen according to design specifications of the semiconductor device 100 to achieve the desired voltage and current performance. The second width W.sub.2 and the third width W.sub.3 can be also changed to control dimensions of the source regions 501 and the drain regions 503.
(31)
(32)
(33) The shallow trench isolation layer is recessed and portion of the fins are exposed in step 707 as discussed above with reference to
(34) The fins are recessed in step 711 and source/drain regions are epitaxially grown in openings of the fins, such as that discussed above with reference to
(35) A method of fabrication an NMOS FinFET device has been described above in reference to
(36) In an embodiment, a semiconductor device comprises a substrate having a plurality of fins extending therefrom, a first well of a first conductivity type in the substrate, a second well of the first conductivity type in the substrate, the first well having a higher dopant concentration than the second well. The semiconductor device further comprises a gate stack overlying a junction between the first well and the second well, a source region of a second conductivity type in the first well, and a drain region of the second conductivity type in the second well.
(37) In an embodiment, a semiconductor device comprises a substrate having a plurality of trenches and fins interposed between adjacent trenches, the substrate being lightly doped with a first conductivity type. The semiconductor device further comprises a first region in the substrate, the first region being doped with the first conductivity type, the first region having a higher dopant concentration than a dopant concentration of the substrate and a second region in the substrate, the second region having the dopant concentration of the substrate. The semiconductor device further comprises a first source/drain region of a second conductivity type in the first region, and a second source/drain region of the second conductivity type in the second region.
(38) In an embodiment, a method of fabricating a semiconductor device comprises providing a substrate, the substrate having a first dopant concentration of a first conductivity type in a first region and a second dopant concentration of the first conductivity type in a second region, the first dopant concentration being greater than the second dopant concentration, the substrate having one or more fins extending therefrom, the one or more fins extending through the first region and the second region. The method further comprises forming a gate stack over the one or more fins, the gate stack overlapping a junction of the first region and the second region, and forming source/drain regions on opposing sides of the gate stack such that a first source/drain region is in the first region and a second source/drain region is in the second region.
(39) According to an embodiment, a semiconductor device includes a substrate having a plurality of trenches and fins interposed between adjacent trenches, a first region in the substrate, the first region being doped with dopants of a first conductivity type, and a second region in the substrate, the second region being doped with the dopants of the first conductivity type, the first region having a higher dopant concentration than the second region. The semiconductor device further includes a gate stack extending over the first region and the second region, a first source/drain region of a second conductivity type in the first region, and a second source/drain region of the second conductivity type in the second region.
(40) According to another embodiment, a semiconductor device includes a substrate having a plurality of fins extending therefrom, and a gate stack overlying a channel portion of the fins, the channel portion of the fins having a first region of a first conductivity type and a second region of the first conductivity type, the first region having a higher dopant concentration than the second region. The semiconductor device further includes a source region embedded in the fins, and a drain region embedded in the fins, the channel portion of the fins being interposed between the source region and the drain region.
(41) According to yet another embodiment, a method of fabricating a semiconductor device is provided. The method includes forming a fin extending from a substrate, the fin having a first region having dopants of a first conductivity type at a first concentration and a second region having dopants of the first conductivity type at a second concentration. After forming the fin, a gate stack is formed over the fin, a first lateral edge of the fin being over the first region and a second lateral edge of the fin being over the second region. Source/drain regions are formed on opposing sides of the gate stack such that a first source/drain region is in the first region and a second source/drain region is in the second region.
(42) According to yet another embodiment, a method of fabricating a semiconductor device is provided. The method includes forming a fin extending from a substrate, the substrate being of a first conductivity type, and forming a first region of the first conductivity type in the fin, the first region being adjacent a second region of the fin, the first region having a first concentration of dopants of the first conductivity type, the second region having a second concentration of dopants of the first conductivity type, the first concentration being greater than the second concentration. After forming the first region, a gate stack is formed over the fin, the gate stack having a first lateral edge over the first region and a second lateral edge over the second region.
(43) According to yet another embodiment, a method of fabricating a semiconductor device is provided. The method includes forming a channel region in a fin, the channel region having a first portion having a first dopant concentration of a first conductivity type and a second portion having a second dopant concentration of the first conductivity type, the first dopant concentration being greater than the second dopant concentration. A source region is formed on a first side of the channel region, the source region having a second conductivity type, and a drain region is formed on a second side of the channel region opposite the first side, the drain region having the second conductivity type. A gate stack is formed over the channel region, the gate stack extending over a junction between the first portion and the second portion.
(44) While this disclosure has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the disclosure, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments.