Semiconductor structures including middle-of-line (MOL) capacitance reduction for self-aligned contact in gate stack
12237368 ยท 2025-02-25
Assignee
Inventors
- Injo Ok (Loudonville, NY, US)
- Balasubramanian Pranatharthiharan (Watervliet, NY, US)
- Soon-Cheon Seo (Glenmont, NY, US)
- Charan V. Surisetty (Clifton Park, NY, US)
Cpc classification
H01L21/76897
ELECTRICITY
H01L21/762
ELECTRICITY
H10D64/259
ELECTRICITY
H10D62/832
ELECTRICITY
H01L21/76849
ELECTRICITY
H10D62/116
ELECTRICITY
H10D84/0149
ELECTRICITY
H01L23/485
ELECTRICITY
H01L21/76829
ELECTRICITY
H01L21/76805
ELECTRICITY
H01L23/53266
ELECTRICITY
H01L21/31056
ELECTRICITY
H10D64/01
ELECTRICITY
International classification
H10D62/10
ELECTRICITY
H01L23/535
ELECTRICITY
H01L21/762
ELECTRICITY
H01L21/3213
ELECTRICITY
H01L23/485
ELECTRICITY
H01L21/768
ELECTRICITY
Abstract
A method of forming a semiconductor structure includes forming a first middle-of-line (MOL) oxide layer and a second MOL oxide layer in the semiconductor structure. The first MOL oxide layer including multiple gate stacks formed on a substrate, and each gate stack of the gate stacks including a source/drain junction. A first nitride layer is formed over a silicide in the first MOL oxide layer. A second nitride layer is formed. Trenches are formed through the second nitride layer down to the source/drain junctions. A nitride cap of the plurality of gate stacks is selectively recessed. At least one self-aligned contact area (CA) element is formed within the first nitride layer. The first MOL oxide layer is selectively recessed. An air-gap oxide layer is deposited. The air gap oxide layer is reduced to the at least one self-aligned CA element and the first nitride layer.
Claims
1. A method of forming a semiconductor structure comprising: providing parallel adjacent gate structures on a substrate, the parallel adjacent gate structures comprising an outer gate structure and an inner gate structure, wherein each of the parallel adjacent gate structures comprises a metal gate and a dielectric gate cap; providing conductive trenches on opposite sides of the inner gate structure; providing a first oxide layer on the dielectric gate caps; providing contact area elements in the first oxide layer, wherein: each of the contact area elements contacts one of the conductive trenches; and upper surfaces of the contact area elements are substantially co-planar with an upper surface of the first oxide layer, etching exposed portions of the first oxide layer to expose the dielectric gate caps; recessing the exposed dielectric gate caps; and depositing a second oxide layer to form airgaps, wherein portions of the airgaps are disposed in regions where the dielectric gate caps were recessed.
2. The method of claim 1, wherein the airgaps extend vertically to a level above a top surface of the conductive trenches.
3. The method of claim 1, comprising: before the etching and the recessing, providing a protective mask on the contact area elements and a portion of the first oxide layer above the inner gate structure.
4. The method of claim 3, wherein the airgaps extend vertically to a level above a top surface of the conductive trenches.
5. The method of claim 1, comprising: providing an insulator layer adjacent to the outer gate structure; and providing the first oxide layer on the insulator layer.
6. The method of claim 1, comprising: recessing the exposed dielectric gate caps to expose the underlying metal gates.
7. The method of claim 1, wherein the outer gate structure is a first outer gate structure, the parallel adjacent gate structures comprise a second outer gate structure, and the method comprises: providing the inner gate structure between the first and second outer gate structures.
8. The method of claim 7, comprising: depositing the second oxide layer to form airgaps in regions above the first outer gate structure, the second outer gate structure, and the internal gate structure, wherein each airgap comprises a portion disposed directly above one of the gate structures.
9. The method of claim 1, wherein the dielectric gate caps comprise nitride.
10. The method of claim 1, wherein the dielectric gate caps comprise SiN.
11. The method of claim 1, wherein the metal gates comprise tungsten.
12. The method of claim 1, wherein the metal gates comprise a metal cap.
13. The method of claim 12, wherein the metal caps comprises cobalt.
14. The method of claim 12, wherein the metal caps comprises ruthenium.
15. The method of claim 1, wherein the metal gates and the contact area elements each comprise a metal cap.
16. The method of claim 1, wherein the contact area elements comprise tungsten.
17. The method of claim 3, wherein the outer gate structure is a first outer gate structure, the parallel adjacent gate structures comprise a second outer gate structure, and the method comprises: providing the inner gate structure between the first and second outer gate structures.
18. The method of claim 17, comprising: depositing the second oxide layer to form airgaps in regions above the first outer gate structure and the second outer gate structure, wherein each airgap comprises a portion disposed directly above one of the gate structures.
19. The method of claim 1, wherein the conductive trenches comprise a silicide.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
DETAILED DESCRIPTION
(32) The descriptions of the various embodiments have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
(33) As used herein, a lengthwise element is an element that extends along a corresponding lengthwise direction, and a widthwise element is an element that extends along a corresponding widthwise direction.
(34) One or more embodiments provide for an integration of semiconductor layers to minimize middle-of-line (MOL) capacitance by introducing air gaps within semiconductor structures. In one or more embodiments, the air gaps are introduced into voids formed in the semiconductor structures. In one embodiment, the formation of the voids are controlled due to the shape of the semiconductor structures. In one or more embodiments, the introduction of air-gaps into the semiconductor structures reduces the capacitance of a MOL oxide layer due to remaining MOL oxide layer reduction, introduced air-gaps and an air-gap oxide layer.
(35)
(36) In one embodiment, the substrate 110 may be a semiconductor-on-insulator (SOI) substrate (e.g., fully-depleted SOI, partially depleted SOI, etc.). In other embodiments, the substrate 100 may be a bulk Fin field effect transistor (FinFET), SOI FinFET, strained SOI (SSOI), SiGe on-insulator (SGOI), Nanowire, etc. In one embodiment, an insulator layer 160 may include exemplary dielectric materials that, for example include, silicon oxide, silicon nitride, silicon oxynitride, and sapphire.
(37) In one embodiment, the gate dielectric of the MG 150 stack includes a high-k material having a dielectric constant greater than silicon oxide. Exemplary high-k materials include, but are not limited to, HfD.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, HfOxNy, ZrOY La.sub.2OxNy, Al.sub.2OxNy, TiOxNy, SrTiOxNy, LaAlOxNy, Y.sub.2OxNy, SiON, SiNx, a silicate thereof, and an alloy thereof. Each value of x is independently from 0.5 to 3 and each value of y is independently from O to 2.
(38) In one embodiment, the gate cavity formed with the multiple depositions, etc. to form the MG 150 stack may be filled with at least one conductive material, such as at least one metallic material and/or at least one doped semiconductor material. Examples of the conductive metal include, but are not limited to, Al, W, Cu, Pt, Ag, Au, Ru, Ir, Rh and Re, alloys of a conductive metal, e.g., AlCu, metal nitrides or carbides such as AN, TiN, TaN, TiC and TaC, silicides of a conductive metal, e.g., W silicide, and Pt silicide, and combinations thereof. The gate electrode of the MG 150 stack can be formed by depositing the conductive material utilizing a conventional deposition process such as, for example, atomic layer deposition (ALD), chemical vapor deposition (CVD), metalorganic chemical vapor deposition (MOCVD), molecular beam epitaxy (MBE), physical vapor deposition (PVD), sputtering, plating, evaporation, ion beam deposition, electron beam deposition, laser assisted deposition, and chemical solution deposition.
(39)
(40)
(41)
(42)
(43)
(44) In one embodiment, the resulting semiconductor device 600 may have a height above the substrate of about 8 nm to 260 nm. In one embodiment, the height of the MG 150 stack is about 50 nm to 150 nm, with a width of less than 30 nm. In one embodiment, the CAs 120 have a height of about 30 nm to 100 nm, and a width of less than 40 nm. In one embodiment, the metal caps 410 have a height of about 1 nm to 10 nm and a width less than 30 nm. In one embodiment, the spacer material 154 and 155 each have a height of about 50 nm to 150 nm and a width of less than 15 nm. In one embodiment, the air-gap oxide layer 510 has a height of about 30 nm to 100 nm. In one embodiment, the height of the air-gap oxide layer 510 from the metal cap 410 to about the remaining MOL oxide layer 130 or to the top of the insulator layer 160 is about 15 nm to 50 nm; and has a height of about 15-50 nm from above the top of the insulator layer 160 to the top of the air-gap oxide layer 510. In one embodiment, the height of the WFM 152 has a height of about 20 nm to 50 nm and a width of less than 30 nm. In one embodiment, the height of the MG 150 is about 30 nm to 199 nm and the width is less than 30 nm.
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54) In one embodiment, process 1500 may further include depositing metal caps (e.g., metal caps 410,
(55) In one embodiment, process 1500 may further include removing the mask from the CA elements and then performing the depositing of the air-gap oxide layer. In one embodiment, the one or more air-gaps reduces capacitance of the MOL oxide layer.
(56) The exemplary methods and techniques described herein may be used in the fabrication of IC chips. In one embodiment, the IC chips may be distributed by a fabricator in raw wafer form (i.e., as a single wafer that has multiple unpackaged IC chips), as a bare die, or in a packaged form. In the latter case, the IC chip is mounted in a single IC chip package (e.g., a plastic carrier with leads that are affixed to a motherboard or other higher level carrier) or in a multi-IC chip package (e.g., a ceramic carrier that has either or both surface interconnections or buried interconnections). The IC chip is then integrated with other IC chips, discrete circuit elements and/or other signal processing devices as part of either (a) an intermediate product, such as a motherboard, or (b) an end product, such as microprocessors, smart phones, mobile phones, cellular handsets, set-top boxes, DVD recorders and players, automotive navigation, printers and peripherals, networking and telecom equipment, gaming systems, toys and digital cameras, as non-limiting examples. One or more embodiments, may be applied in any of various highly integrated semiconductor devices.
(57) Unless described otherwise or in addition to that described herein, depositing may include any now known or later developed techniques appropriate for the material to be deposited, including, but not limited to: CVD, LPCVD, PECVD, semi-atmosphere CVD (SACVD), high density plasma CVD (HDPCVD), rapid thermal CVD (RTCVD), ultra-high vacuum CVD (UHVCVD), limited reaction processing CVD (LRPCVD), metalorganic CVD (MOCVD), sputtering deposition, ion beam deposition, electron beam deposition, laser assisted deposition, thermal oxidation, thermal nitridation, spin-on methods, PVD, ALD, chemical oxidation, MBE, plating or evaporation. Any references to poly or poly silicon should be understood to refer to polycrystalline silicon.
(58) References herein to terms such as vertical, horizontal, etc. are made by way of example, and not by way of limitation, to establish a frame of reference. The term horizontal as used herein is defined as a plane parallel to the conventional plane or surface of the substrate, regardless of the actual spatial orientation of the semiconductor substrate. The term vertical refers to a direction perpendicular to the horizontal, as just defined. Terms, such as on, above, below, side (as in sidewall), higher, lower, over, beneath and under, are defined with respect to the horizontal plane. It is understood that various other frames of reference may be employed for describing one or more embodiments without departing from the spirit and scope of the one or more embodiments.
(59) References in the claims to an element in the singular is not intended to mean one and only unless explicitly so stated, but rather one or more. All structural and functional equivalents to the elements of the above-described exemplary embodiment that are currently known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the present claims. No claim element herein is to be construed under the provisions of 35 U.S.C. section 112, sixth paragraph, unless the element is expressly recited using the phrase means for or step for.
(60) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the embodiments. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, steps, operations, elements, materials, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, materials, components, and/or groups thereof.
(61) The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present embodiments has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the embodiments. The embodiments were chosen and described in order to best explain the principles of the embodiments and the practical application, and to enable others of ordinary skill in the art to understand the various embodiments with various modifications as are suited to the particular use contemplated.