STRAINED-CHANNEL FIN FETS
20250126850 ยท 2025-04-17
Assignee
Inventors
Cpc classification
H10D30/797
ELECTRICITY
H10D62/832
ELECTRICITY
H10D30/6211
ELECTRICITY
H10D62/822
ELECTRICITY
International classification
H10D30/69
ELECTRICITY
H10D30/01
ELECTRICITY
H10D62/83
ELECTRICITY
H10D62/822
ELECTRICITY
H10D62/832
ELECTRICITY
Abstract
Methods and structures for forming strained-channel finFETs are described. Fin structures for finFETs may be formed in two epitaxial layers that are grown over a bulk substrate. A first thin epitaxial layer may be cut and used to impart strain to an adjacent channel region of the finFET via elastic relaxation. The structures exhibit a preferred design range for increasing induced strain and uniformity of the strain over the fin height.
Claims
1. A method, comprising: forming a first fin adjacent to a second fin by: forming a first semiconductor layer on a second semiconductor layer; forming a first spacer structure and a second spacer structure on the first and second semiconductor layers, each of the first spacer structure and the second spacer structure being in the range of 5 and 30 nanometers; and removing portions of the first and second semiconductor layers.
2. The method of claim 1 wherein forming the first spacer structure includes forming a plurality of mask bars on the first and second semiconductor layers and forming the first and second spacer structure adjacent to sidewalls of a first one of the plurality of mask bars.
3. The method of claim 2, comprising forming a third fin adjacent to the second fin by forming a third spacer structure on sidewalls of a second one of the plurality of mask bars.
4. The method of claim 1 comprising: forming the first fin spaced from the second fin by a first dimension; forming a third fin spaced from the second fin by a second dimension that is different from the first dimension.
5. The method of claim 4 comprising: forming a fourth fin spaced from the third fin by the first dimension, the second fin being between the first fin and the third fin and the third fin being between the second fin and the fourth fin.
6. The method of claim 5 comprising: forming a fifth fin spaced from the fourth fin by the second dimension, the fourth fin being between the third fin and the fifth fin.
7. The method of claim 6 wherein the first dimension is in the range of 10 and 50 nanometers.
8. The method of claim 7 wherein the second dimension is in the range of 10 and 50 nanometers.
9. A method, comprising: forming a first fin and a second fin on a substrate, the forming of the first fin and the second fin including: forming a first semiconductor layer on the substrate; forming a second semiconductor layer on the first semiconductor layer; forming a first spacer structure and a second spacer structure on the first and second semiconductor layers, each of the first spacer structure and the second spacer structure being in the range of 5 and 30 nanometers; removing portions of the first and second semiconductor layers.
10. The method of claim 9 comprising removing the first and second spacer structures.
11. The method of claim 9 comprising forming the first fin next to the second fin on the substrate and forming a third fin next to the second fin on the substrate, the second fin being between the first fin and the third fin.
12. A device, comprising: a substrate; a first fin adjacent to a second fin on the substrate, each of the first and second fins including: a first semiconductor layer on a second semiconductor layer; a first dimension in a first direction that is substantially parallel to the substrate, the first dimension being in the range of 5 and 30 nanometers.
13. The device of claim 12, comprising: a third fin adjacent to the second fin on the substrate, the third fin being spaced from the second fin by a second dimension, the first fin being spaced from the second fin by a third dimension, the second dimension being different from the third dimension.
14. The device of claim 13 wherein the second dimension is the range of 10 and 50 nanometers.
15. The device of claim 14 wherein the third dimension the range of 10 and 50 nanometers.
16. The device of claim 13 wherein the third fin includes the first and second semiconductors layers.
17. The device of claim 16 wherein the third fin has a fourth dimension in the first direction, the fourth dimension being in the range of 5 and 30 nanometers.
18. The device of claim 13, comprising a fourth fin adjacent to the third fin on the substrate, the fourth fin being spaced from the third fin by the third dimension.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] The skilled artisan will understand that the figures, described herein, are for illustration purposes only. It is to be understood that in some instances various aspects of the embodiments may be shown exaggerated or enlarged to facilitate an understanding of the embodiments. In the drawings, like reference characters generally refer to like features, functionally similar and/or structurally similar elements throughout the various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the teachings. Where the drawings relate to microfabrication of integrated devices, only one device may be shown of a large plurality of devices that may be fabricated in parallel. The drawings are not intended to limit the scope of the present teachings in any way.
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[0018] The features and advantages of the embodiments will become more apparent from the detailed description set forth below when taken in conjunction with the drawings.
DETAILED DESCRIPTION
[0019] As noted above, finFETs exhibit favorable current-to-size switching capabilities for integrated circuits, and finFETs like those shown in
[0020] In some cases, speed, junction leakage current, and/or breakdown voltage considerations may create a need for semiconductor material other than silicon. For example, SiGe can exhibit higher mobilities for electrons and holes, higher device speed, and lower junction leakage than bulk Si. As a result, some devices may be fabricated from SiGe that is epitaxially grown on a silicon substrate. However, conventional epitaxial growth of SiGe for forming integrated devices has some attributes that may not be favorable for certain applications. For example, because of a lattice constant mismatch between SiGe and Si, strain is induced in the SiGe as it is epitaxially grown. In some cases, the strain causes dislocations or defects in the SiGe during its growth, which can adversely affect device performance to unacceptable levels. To mitigate effects of strain, a thick epitaxial layer of SiGe may be grown so that the strain is relieved over an appreciable distance. Depending upon the dopant concentration, SiGe epitaxial layers 1-10 microns thick may be necessary, and plastic relaxation may occur in the material causing defects. Such an approach may require long and complex epitaxy steps (e.g., it may be necessary to vary dopant concentration during the epitaxial growth), and may further require a thermal annealing step and chemical-mechanical polishing step to planarize a surface of the SiGe after its growth. The annealing may reduce some defects generated during epitaxial growth of SiGe, but typically the defects may not be reduced below 10.sup.5 defects/cm.sup.2, a level not suitable for many industrial applications.
[0021] Straining of silicon can be used to improve some of its electrical properties. For example compressive straining of silicon can improve the hole mobility within silicon. Tensile straining of Si can improve electron mobility. The inventors have recognized and appreciated that inducing strain in silicon can be used to fabricate integrated electronic devices with performance that is competitive with SiGe devices. For smaller devices, e.g., sub-20-nm channel-width FETs such as finFETs, the avoidance of thick (>1 micron) SiGe epitaxial layers and increased device performance from strain may be important factors in the manufacturability of the strained devices. As an example of inducing strain in an integrated, three-dimensional device, described below are methods for making strained-Si-channel finFET devices. Although the embodiments are directed to a strained-channel Si finFET, the method of inducing strain may be extended to other devices or structures, in which other materials may be used.
[0022] A strained-channel finFET 102 may appear as depicted in
[0023]
[0024] According to some embodiments, a process for forming a strained-channel finFET may begin with a substrate 110 of a first semiconductor material upon which an insulator 105 may be formed, as depicted in
[0025] The terms approximately and about may be used to mean within 20% of a target dimension in some embodiments, within 10% of a target dimension in some embodiments, within 5% of a target dimension in some embodiments, and yet within 2% of a target dimension in some embodiments. The terms approximately and about may include the target dimension.
[0026] With reference to
[0027] Where the substrate surface is exposed, a second semiconductor material (e.g., SiGe or SiC) may be epitaxially grown over the surface to form a strain-inducing layer 220. Subsequently, a device layer 210 of the first semiconductor material may be epitaxially grown over the second semiconductor material. Because of the epitaxial growth of the strain-inducing layer 220 and the device layer 210, the crystalline quality at the device layer 210 is high. For example, it may have a defect density less than 10.sup.5 defects/cm.sup.2 in some embodiments, less than 10.sup.4 defects/cm.sup.2 in some embodiments, less than 10.sup.3 defects/cm.sup.2 in some embodiments, and yet less than less than 10.sup.2 defects/cm.sup.2 in some embodiments. According to some embodiments, the device layer 210 forms a layer in which fins for strained-channel finFETs may be formed. In some embodiments, the semiconductor material of the device layer 210 may be different than the semiconductor material of the substrate.
[0028] The thickness of the device layer 210 may be between 5 nm and 100 nm in some embodiments, between 10 nm and 60 nm in some embodiments, and in some embodiments may between about 15 nm and 30 nm. The thickness of the strain-inducing layer 220 may be between 5 nm and 100 nm in some embodiments, between 10 nm and 60 nm in some embodiments, and in some embodiments may be between 30 nm and 50 nm.
[0029] The fins may be patterned by a sidewall image transfer (SIT) process that is depicted by steps illustrated in
[0030] On the hard mask layer 230 an insulating layer 240 may be formed. The insulating layer may comprise undoped silicate glass (USG), and its thickness may be between 10 nm and 100 nm in some embodiments, between 20 nm and 50 nm in some embodiments, and in some embodiments may be about 30 nm. In some embodiments, the insulating layer 240 may be applied by any suitable means, e.g., via physical deposition, a plasma deposition process, or a spin-on and anneal process.
[0031] A patterning layer 250 may be deposited over the insulating layer 240. In some embodiments, the patterning layer 250 may comprise amorphous silicon that is deposited by a plasma deposition process, though any suitable material may be used. The patterning layer 250 may be between 10 nm and 100 nm in some embodiments, between 20 nm and 50 nm in some embodiments, and in some embodiments may be about 40 nm.
[0032] Referring to
[0033] A blanket masking layer (not shown) may be deposited over the bar-like structures 252 and insulating layer 240. In some embodiments, the blanket masking layer may comprise silicon nitride that is deposited by a plasma deposition process. The thickness of the masking layer may be between 50 nm and 100 nm in some embodiments, between 5 nm and 50 nm in some embodiments, and in some embodiments may be between about 5 nm and about 20 nm. The blanket masking layer may be etched away to form spacer structures 232, as depicted in
[0034] For example, a first selective, anisotropic etch may be performed to remove the bar-like structures 252. The same etch recipe, or a different etch recipe may be used to remove most of the insulating layer 240, thereby transferring the pattern of the spacer structures 232 to the insulating layer. The resulting structure may appear as depicted in
[0035] As noted above, the strain-inducing layer 220 forms in a strained state during its epitaxial growth due to a lattice mismatch between the material used for the strain-inducing layer and the substrate. As an example, a SiGe strain-inducing layer will form with compressive strain when grown on a bulk Si substrate. The amount of strain in the SiGe layer can be controlled to some extent by controlling the Si:Ge ratio. The combination of etching the fin structures 115 through the strain-inducing layer and removing the hard mask feature 234 allows the strain-inducing material to relax locally at each fin and relieve some of its strain. In doing so, the strain-inducing layer imparts strain (tensile in this case) to the adjacent fin formed in the device layer 210 where the channel of a finFET will be formed. Because of the narrow and long fin structures, the resulting strain in the device fins will be substantially uniaxial, longitudinal strain along the length of the fin. According to some embodiments, relaxation of the strain-inducing layer may be purely elastic, such that no appreciable defects are generated.
[0036] To investigate the induced strain imparted to the fin, numerical simulations based on finite element analysis were carried out. These computations show that the amount of strain in the device fin and its uniformity can be controlled through several device design parameters. Among the controlling parameters are lattice mismatch between the strain-inducing layer and substrate (controllable through choice of materials and/or dopant concentrations), thickness or height of the strain-inducing layer, thickness or height of the fin, and length of the fin.
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[0041] Based upon the results of
where L represents the fin length, T.sub.si represents the thickness of the strain-inducing layer, and T.sub.f represents the thickness of the device layer. According to some embodiments, a design parameter R.sub.sc for strained-channel finFETs may be within a range given approximately by 2.55R.sub.sc3.12. According to some embodiments, a design parameter R.sub.sc for strained-channel finFETs may be within a range given approximately by 2.65R.sub.sc3.03.
[0042] The results shown in
[0043] The fins shown in the drawings may be spaced laterally from each other on one or more regular spacing intervals. For example, there may be a uniform lateral spacing d.sub.1 between all fins. Alternatively, there may be two uniform lateral spacings d.sub.1, d.sub.2 alternating between successive fins. The fins may have a width between approximately 5 nm and approximately 30 nm. The fins may be spaced apart between approximately 10 nm and approximately 50 nm, in some embodiments. There may be one or more fins per finFET device. A gate structure, like that shown in
[0044] A finFET device fabricated according to the present teachings may be formed in an integrated circuit in large numbers and/or at high densities. The circuits may be used for various low-power applications, including but not limited to, circuits for operating smart phones, computers, tablets, PDA's, video displays, and other consumer electronics. For example, a plurality of finFETs fabricated in accordance with the disclosed embodiments may be incorporated in processor or control circuitry used to operate one of the aforementioned devices.
[0045] The discussion above is directed primarily to a SiGe strain-inducing layer that imparts tensile stress to a fin of a finFET device. Accordingly, for a Si finFET, the use of SiGe for the strain-inducing layer may improve the electron mobility for n-channel finFETs. For p-channel finFETs, SiC may be used as the strain-inducing layer. SiC can impart compressive stress to a fin. In alternative embodiments for which an active fin and channel may be formed in SiGe, the materials may be reversed. For example, Si may be epitaxially grown on a SiGe substrate or base layer to form a strain-inducing layer of Si. The device layer may then be SiGe.
[0046] In alternative embodiments, the cutting of the strain-inducing layer need not be at the same time and/or of the same shape as the patterning of the adjacent device layer. In the above example of a strained-channel finFET, a device may be patterned in the device layer 210 in a first step. At later time, the strain-inducing layer 220 may be etched in the vicinity of the device fin, so as to cut the strain-inducing layer and induce strain in the device fin. The etched pattern in the strain-inducing layer may be different from the pattern used to etch the device fin.
[0047] The techniques may be applied to other types of finFETs, e.g., fully insulated finFETs, and other microfabricated devices and structures such as MEMs devices. In some embodiments, the techniques may be used in LEDs or laser diodes to strain the device and adjust emission wavelength. According to some embodiments, a strain-inducing layer may be used to impart stress to any three-dimensional structure patterned into a device layer that has been formed adjacent the strain-inducing layer. For example, a three-dimensional device or structure may be patterned in the device layer, and the strain-inducing layer may be cut (e.g., etched) in the vicinity of the patterned device or structure to relieve strain in the strain-inducing layer and impart strain to the adjacent patterned feature.
[0048] In some embodiments, the strain-inducing layer and/or adjacent device layer may comprise a material other than semiconductor material, e.g., crystalline insulator, an oxide, a ceramic, etc. In some embodiments, the strain-inducing layer and/or device layer may be formed by methods other than epitaxial growth, e.g., plasma deposition, plasma deposition and annealing, sputtering, etc. According to some embodiments, a thin insulating layer may be formed between the strain-inducing layer and the device layer where the fin is formed. In some embodiments, at least a portion of the strain-inducing layer may comprise an active region or portion of the formed device.
[0049] The technology described herein may be embodied as a method, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. Additionally, a method may include more acts than those illustrated, in some embodiments, and fewer acts than those illustrated in other embodiments.
[0050] Having thus described at least one illustrative embodiment of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto.