THREE-DIMENSIONAL FINFET TRANSISTOR WITH PORTION(S) OF THE FIN CHANNEL REMOVED IN GATE-LAST FLOW
20170069759 ยท 2017-03-09
Assignee
Inventors
Cpc classification
H10D30/6212
ELECTRICITY
H10D30/0223
ELECTRICITY
H10D62/116
ELECTRICITY
H10D30/0245
ELECTRICITY
International classification
H01L29/66
ELECTRICITY
H01L29/06
ELECTRICITY
Abstract
A three-dimensional transistor includes a channel with a center portion (forked channel) or side portions (narrow channel) removed, or fins without shaping, after removal of the dummy gate and before a replacement metal gate is formed.
Claims
1. A method, comprising: providing a starting three-dimensional semiconductor structure, the structure comprising a semiconductor substrate and at least one fin coupled thereto, the at least one fin each comprising a channel region in a top center thereof; and removing at least one center portion of at least one channel region, resulting in a forked cross-sectional shape for the at least one channel region.
2. The method of claim 1, wherein the at least one portion of the at least one channel region removed exposes the substrate, creating a pair of fins for each with the at least one portion of the at least one fin removed, the method further comprising forming a layer of isolation material around a bottom portion of the fins after removal of the center portion.
3. The method of claim 1, further comprising forming a layer of isolation material around a bottom portion of the at least one fin prior to the removing.
4. The method of claim 1, further comprising forming a layer of isolation material around a bottom portion of the at least one fin prior to the removing, wherein the removing comprises removing side portions of the at least one fin down to the isolation layer.
5. (canceled)
6. A method, comprising: providing a starting semiconductor structure, the structure comprising a semiconductor substrate; forming at least one U-shaped member of hard mask material over the substrate, the U-shaped member being filled with at least one filler material; removing portions of the substrate not covered by the at least one U-shaped member, the removing forming one or more fins; and forming a layer of isolation material about a bottom portion of the fins.
7. The method of claim 6, further comprising; removing vertical sections of the hard mask material on both sides of the filler layer; removing side portions of the fin body down to the layer of isolation material; and removing remaining portions of the filler layer.
8. The method of claim 6, further comprising removing the at least one filler material, leaving a U-shaped member of hard mask material atop each fin.
9. The method of claim 8, further comprising: extending an opening in each U-shaped member into a body of the at least one fin; and removing any remaining hard mask material.
10. The method of claim 6, further comprising forming at least one dummy gate structure, the structure comprising a dummy gate and spacers.
11. The method of claim 10, further comprising forming epitaxial semiconductor material adjacent each spacer and isolation material over the epitaxial semiconductor material.
12. The method of claim 11, further comprising replacing the dummy gate with conductive material and a gate cap.
13. The method of claim 6, wherein the starting semiconductor structure further comprises a hard mask layer over the substrate, a layer of at least one filler material over the hard mask layer and a layer of amorphous carbon over the filler layer, the forming comprising: removing portions of the layer of amorphous carbon to create a plurality of mandrels; forming a conformal layer of hard mask material over the structure and mandrels; removing horizontal portions of the conformal layer of hard mask material and the mandrels, leaving vertical sections of the conformal layer; removing the filler material everywhere except for vertical portions directly below each vertical section of the conformal layer; removing the vertical sections of the conformal layer, leaving vertical sections of the filler material; and forming a blanket conformal layer of hard mask material over the structure.
14. The method of claim 13, further comprising: removing exposed horizontal sections of the blanket conformal layer of hard mask material; and forming a layer of isolation material surrounding a lower portion of the fins.
15. A semiconductor structure, comprising: a semiconductor substrate; at least one semiconductor fin coupled to the substrate, the at least one fin comprising a source region, a drain region and a channel region therebetween; and isolation material surrounding a bottom portion of the at least one fin; wherein at least one portion of the channel region has been removed; and wherein the at least one portion comprises a center portion, and wherein a cross-section of the channel region has a forked shape.
16. (canceled)
17. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
[0035] Aspects of the present invention and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting examples illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific examples, while indicating aspects of the invention, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions, and/or arrangements, within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.
[0036] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as about, is not limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value.
[0037] The terminology used herein is for the purpose of describing particular examples only and is not intended to be limiting of the invention. 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 comprise (and any form of comprise, such as comprises and comprising), have (and any form of have, such as has and having), include (and any form of include, such as includes and including), and contain (and any form of contain, such as contains and containing) are open-ended linking verbs. As a result, a method or device that comprises, has, includes or contains one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of a device that comprises, has, includes or contains one or more features possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, a device or structure that is configured in a certain way is configured in at least that way, but may also be configured in ways that are not listed.
[0038] As used herein, the term connected, when used to refer to two physical elements, means a direct connection between the two physical elements. The term coupled, however, can mean a direct connection or a connection through one or more intermediary elements.
[0039] As used herein, the terms may and may be indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of may and may be indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable or suitable. For example, in some circumstances, an event or capacity can be expected, while in other circumstances the event or capacity cannot occurthis distinction is captured by the terms may and may be.
[0040] Reference is made below to the drawings, which are not drawn to scale for ease of understanding, wherein the same reference numbers are used throughout different figures to designate the same or similar components.
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[0042] The starting structure may be conventionally fabricated, for example, using known processes and techniques. Further, unless noted otherwise, conventional processes and techniques may be used to achieve individual steps of the fabrication process of the present invention. However, although only a portion is shown for simplicity, it will be understood that, in practice, many such structures are typically included on the same bulk substrate.
[0043] In one example, substrate 102 may include any silicon-containing substrate including, but not limited to, silicon (Si), single crystal silicon, polycrystalline Si, amorphous Si, silicon-on-nothing (SON), silicon-on-insulator (SOI) or silicon-on-replacement insulator (SRI) or silicon germanium substrates and the like. Substrate 102 may in addition or instead include various isolations, dopings and/or device features. The substrate may include other suitable elementary semiconductors, such as, for example, germanium (Ge) in crystal, a compound semiconductor, such as silicon carbide (SiC), gallium arsenide (GaAs), gallium phosphide (GaP), indium phosphide (InP), indium arsenide (InAs), and/or indium antimonide (InSb) or combinations thereof; an alloy semiconductor including GaAsP, AlInAs, GaInAs, GaInP, or GaInAsP or combinations thereof.
[0044] The non-planar structure further includes at least one raised semiconductor structure 104 (raised with respect to the substrate). In one example, the raised structures may take the form of a fin. The raised structure(s) may be etched from a bulk substrate, and may include, for example, any of the materials listed above with respect to the substrate. Further, some or all of the raised structure(s) may include added impurities (e.g., by doping), making them n-type or p-type. The structure further includes at least one gate structure surrounding channel region 106 (omitted for clarity) with spacers 108 surrounding a portion of one or more of the raised structures 104.
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[0064] It should be noted here that any fin reshaping (e.g., as in
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[0070] At this point, the flow continues with conventional replacement metal gate process (RMG) steps, for example, deposition of high-k and work-function, conductive electrode materials, etc.
[0071] The conventional flow, some of which is excluded in the figures for brevity, started with fin formation and STI, and continues with well formation, active fin reveal, dummy gate structure formation, n and p-type junction formation, replacement gate formation, silicide and contact formation, and BEOL interconnections. Part of the process of replacement gate formation is to remove the dummy gate material (e.g., polysilicon) and form a layer of dielectric, typically high-k, work-function layers, and conductive electrode layer.
[0072] The present invention flow precedes polysilicon removal and high-k formation with the following flow. The dummy gate material is exposed selectively (
[0073] Note that if a first level fin (i.e., wider fin) is not desired, simply skip the appropriate steps. This would result in all fins being narrow. Note also that the wider fins can have a different threshold voltage (Vt) than the narrow ones, such that a two Vt scheme on FinFETs can be achieved.
[0074] In a first aspect, disclosed above is a method. The method includes providing a starting three-dimensional semiconductor structure, the structure including a semiconductor substrate and fin(s) coupled thereto, the fin(s) each including a channel region in a top center thereof, and removing portion(s) of the channel region(s).
[0075] In one example, the portion(s) of the channel region(s) removed exposes the substrate, creating a pair of fins for each with the portion(s) of the fin(s) removed, and the method may further include, for example, forming a layer of isolation material around a bottom portion of the fin(s) after removal of the center portion.
[0076] In one example, the method of the first aspect may further include, for example, forming a layer of isolation material around a bottom portion of the fin(s) prior to the removing.
[0077] In one example, the method of the first aspect may further include, for example, forming a layer of isolation material around a bottom portion of the fin(s) prior to the removing, the removing includes removing side portions of the fin(s) down to the isolation layer.
[0078] In one example, the removing in the method of the first aspect may include, for example, removing side portions of the fin(s), and the method may further include, for example, forming a layer of isolation material around a bottom portion of the fin(s) after the removing.
[0079] In a second aspect, disclosed above is a method. The method includes providing a starting semiconductor structure, the structure including a semiconductor substrate. The method further includes forming U-shaped member(s) of hard mask material over the substrate, the U-shaped member(s) being filled with filler material(s), removing portions of the substrate not covered by the U-shaped member(s), the removing forming fin(s), and forming a layer of isolation material about a bottom portion of the fins.
[0080] In one example, the method may further include, for example, removing vertical sections of the hard mask material on both sides of the filler layer, removing side portions of the fin body down to the layer of isolation material, and removing remaining portions of the filler layer.
[0081] In one example, the method of the second aspect may further include, for example, removing the filler material(s), leaving a U-shaped member of hard mask material atop each fin.
[0082] In one example, the method may further include, for example, extending an opening in each U-shaped member into a body of the fin(s), and removing any remaining hard mask material.
[0083] In one example, the method of the second aspect may further include, for example, forming dummy gate structure(s), the structure(s) including a dummy gate and spacers.
[0084] In one example, the method may further include, for example, forming epitaxial semiconductor material adjacent each spacer and isolation material over the epitaxial semiconductor material.
[0085] In one example, the method may further include, for example, replacing the dummy gate with conductive material and a gate cap.
[0086] In one example, the starting semiconductor structure in the method of the second aspect may further include, for example, a hard mask layer over the substrate, a layer of filler material(s) over the hard mask layer and a layer of amorphous carbon over the filler layer. Further, the forming in the method of the second aspect may include, for example, removing portions of the layer of amorphous carbon to create mandrels, forming a conformal layer of hard mask material over the structure and mandrels, removing horizontal portions of the conformal layer of hard mask material and the mandrels, leaving vertical sections of the conformal layer, removing the filler material everywhere except for vertical portions directly below each vertical section of the conformal layer, removing the vertical sections of the conformal layer, leaving vertical sections of the filler material, and forming a blanket conformal layer of hard mask material over the structure.
[0087] In one example, the method of the second aspect may further include, for example, removing exposed horizontal sections of the blanket conformal layer of hard mask material, and forming a layer of isolation material surrounding a lower portion of the fin(s).
[0088] In a third aspect, disclosed above is a semiconductor structure. The structure includes a semiconductor substrate, semiconductor fin(s) coupled to the substrate, the fin(s) including a source region, a drain region and a channel region therebetween, and isolation material surrounding a bottom portion of the fin(s), portion(s) of the channel region having been removed.
[0089] In one example, the portion(s) include a center portion, such that a cross-section of the channel region has a forked shape.
[0090] In another example, the portion(s) include side portions of the channel region, resulting in a narrower fin in the channel region.
[0091] While several aspects of the present invention have been described and depicted herein, alternative aspects may be effected by those skilled in the art to accomplish the same objectives. Accordingly, it is intended by the appended claims to cover all such alternative aspects as fall within the true spirit and scope of the invention.