3D VERTICAL NANO SHEET TRANSISTOR DESIGN USING SEMICONDUCTIVE OXIDES AND INSULATORS FOR NANO SHEET CORES
20230207624 · 2023-06-29
Assignee
Inventors
- Mark I. Gardner (Cedar Creek, TX)
- H. Jim Fulford (Marianna, FL, US)
- Partha MUKHOPADHYAY (Oviedo, FL, US)
Cpc classification
H01L27/088
ELECTRICITY
H01L29/42392
ELECTRICITY
H01L21/823475
ELECTRICITY
H01L29/7789
ELECTRICITY
H01L21/823418
ELECTRICITY
H01L21/823412
ELECTRICITY
H01L29/24
ELECTRICITY
H01L21/823871
ELECTRICITY
H01L29/78696
ELECTRICITY
International classification
H01L29/06
ELECTRICITY
H01L21/8234
ELECTRICITY
H01L29/417
ELECTRICITY
H01L29/423
ELECTRICITY
Abstract
A method of forming a vertical channel transistor includes forming a first source-drain (SD) contact on a semiconductor substrate, depositing a layer of vertical channel core material on the first SD contact and depositing a layer of second SD contact material on the layer of channel core material. Also included is pattern etching the layer of second SD contact material and the layer of channel core material to form a vertical channel core having a first end connected to the first SD contact and a second end opposite to the first end and connected to a second SD contact formed by the etching the layer of second SD contact material. A vertical channel structure is formed on a sidewall of the vertical channel core, and a gate-all-around (GAA) structure is formed to completely surrounding at least a portion of the vertical channel structure.
Claims
1. A method of forming a vertical channel transistor, including: forming a first source-drain (SD) contact on a semiconductor substrate; depositing a layer of vertical channel core material on the first SD contact; depositing a layer of second SD contact material on the layer of channel core material; pattern etching the layer of second SD contact material and the layer of channel core material to form a vertical channel core having a first end connected to the first SD contact and a second end opposite to the first end and connected to a second SD contact formed by the etching the layer of second SD contact material; forming a vertical channel structure on a sidewall of the vertical channel core; and forming a gate-all-around (GAA) structure completely surrounding at least a portion of the vertical channel structure at a position between the first SD contact and the second SD contact.
2. The method of claim 1, wherein the forming a first SD contact includes forming a conductive routing layer connected to the first SD contact.
3. The method of claim 1, wherein the depositing a layer of vertical channel core material include depositing at least one of a layer of dielectric core material and a layer of conductive oxide core material on the first SD contact.
4. The method of claim 1, wherein the forming a vertical channel structure on a sidewall of the vertical channel core includes forming a channel structure of 2D material on the sidewall of the vertical channel core.
5. The method of claim 1, wherein the forming a vertical channel structure on a sidewall of the vertical channel core includes forming a channel structure of conductive oxide material on the sidewall of the vertical channel core.
6. The method of claim 1, wherein the forming a gate-all-around (GAA) structure includes: forming a gate dielectric layer completely surrounding at least a portion of the vertical channel structure at a position between the first SD contact and the second SD contact; and forming a gate metal layer completely surrounding the gate dielectric layer.
7. The method of claim 6, wherein: the forming a gate dielectric layer includes performing atomic layer deposition (ALD) of the gate dielectric layer; and the forming a gate metal layer includes performing ALD of the gate metal layer.
8. The method of claim 7, further including directionally etching the gate metal layer to form the GAA structure.
9. The method of claim 1, further including: forming a first metal connection to the second SD contact; and forming a second metal connection to the GAA structure.
10. The method of claim 1, wherein the vertical channel transistor is a lower tier transistor formed in a formed in a lower tier of side-by-side vertical channel transistors.
11. The method of claim 10, further including forming an upper tier vertical channel transistor in an upper tier of side-by-side vertical channel transistors provided over the lower tier of transistors, wherein at least one upper tier vertical channel transistor is electrically connected to the lower tier transistor.
12. The method of claim 11, further including forming an interconnect layer between the lower tier and the upper tier of vertical channel transistors.
13. The method of claim 1, further including laterally etching a sidewall of the vertical channel core to form a recessed sidewall before the forming a vertical channel structure.
14. The method of claim 13, wherein the forming a vertical channel structure includes: depositing a conformal layer of conductive oxide material on the substrate to cover the recessed sidewall; and depositing a conformal layer of 2D material on the layer of conductive oxide material.
15. The method of claim 14, wherein the forming a vertical channel structure further includes directionally etching the layer of conductive oxide material and the layer of 2D material such that the vertical channel structure remains on the recessed sidewall of the vertical channel core.
16. The method of claim 14, further including forming the gate-all-around (GAA) structure completely surrounding at least a portion of the vertical channel structure remaining on the recessed sidewall of the vertical channel core.
17. A method of microfabrication, the method including: forming a first wiring layer over a substrate, the first wiring layer including source-drain (SD) contact structures; forming a first dielectric layer over the first wiring layer; patterning and etching the first dielectric layer to form channel structures from the first dielectric layer, the first dielectric layer being etched until uncovering the first wiring layer; forming 2D material on sidewalls of the channel structures; depositing a second dielectric on the 2D material; and forming gate structures all around a cross section of the channel structures, the channel structures having a current flow direction perpendicular to the first metal wiring layer.
18. The method of claim 17, further including forming a second wiring layer over the channel structures having second SD contact structures.
19. The method of claim 18, wherein the channel structures and gate structures and SD contact structures define a first transistor plane of vertical channel transistors.
20. The method of claim 19, further including forming a second plane of vertical channel transistors over the first plane of vertical channel transistors.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Various embodiments of this disclosure that are proposed as examples will be described in detail with reference to the following figures, wherein like numerals reference like elements, and wherein:
[0027]
[0028]
[0029]
[0030]
[0031]
DETAILED DESCRIPTION OF EMBODIMENTS
[0032] As noted in the Background, 3D integration for logic chips, GPUs, FPGAs, and SoC for example is being pursued. The present inventors recognized that semiconductive materials that can be formed/deposited on a substrate without requiring a seed layer and/or at processing temperatures lower than 600 degrees Celsius are beneficial in forming vertical stacks or planes of transistors (e.g., 3D transistors). In contrast, semiconductors used to make conventional semiconductor devices are often formed by epitaxy, which requires a seed layer for growth. Requiring a seed layer can mean a need to uncover a particular material on a substrate that might be covered by many layers and structures. As appreciated by the present inventors, without needing to integrate access to a seed layer into a given fabrication flow, a semiconductive material can be easily formed over an existing plane of transistors to create an additional plane of transistors. Moreover, formation of conventional semiconductors can require high temperature deposition and annealing (e.g., greater than about 600 degrees Celsius). After initial high temperature processing, additional materials are added that may not tolerate high temperature processing. This means that if a first plane of transistors is formed, adding a second plane of transistors that needs high temperature processing can damage the first plane of transistors, leading to device failure. Accordingly, semiconductor materials that can be formed at less than 600 degrees Celsius are desirable. Without requiring a seed layer or high temperature processing, semiconductive materials herein can be formed on many different surfaces, easily integrate with various fabrication flows, and help enable vertical stacking of transistors.
[0033] Techniques disclosed herein may use alternative semiconductors in the microfabrication of semiconductor devices. Such semiconductors herein can be alternatives to silicon, germanium, gallium arsenide, and other commonly used semiconductors. Semiconductors and structures herein can include semiconductive oxides, semiconductive 2D materials, and semiconductive materials. This includes semiconductors (materials) that can be formed at relatively low temperatures and without epitaxy.
[0034] Several example embodiments using alternative semiconductive materials for implementing 3D integration are disclosed herein.
[0035]
[0036] The Si layer 101 may alternatively be made from semiconductor materials such as Ge, SiGe, GaAs, InAs, InP, semiconductive behaving oxide (e.g. In.sub.2O.sub.3, SnO.sub.2, InGaZnO, and ZnO, SnO), 2D material (e.g. WS.sub.2, WSe.sub.2, WTe.sub.2, MoS.sub.2, MoSe.sub.2, MoTe.sub.2, HfS.sub.2, ZrS.sub.2, TiS.sub.2, GaSe, InSe, phosphorene, HfSe.sub.2, ZrSe.sub.2, HfZrSe.sub.2, etc.) or any other suitable semiconductor material in monocrystalline and/or polycrystalline form. Semiconductive behaving oxides and 2D materials may also be used for forming vertical channel structures as discussed further below.
[0037] Dielectric 201 is then deposited over the SD contact 105 and metal routing lines 107 as shown in
[0038]
[0039] Materials for the channel and gate dielectric are then deposited as shown in
[0040] The vertical channel and gate dielectric structures are then formed, followed by depositing gate metal material as shown in
[0041] The gate-all-around (GAA) structure is then formed for the vertical transistors, and SD and GAA connections are formed as shown in
[0042] The transistor connections are then formed by depositing a dielectric 603 over the substrate and performing photolithography and directional etching of the dielectric 603 to form pattern openings which are then filled with conductive material such as metal to provide SD connections 605 and GAA connections 607. Etch of dielectric 603 is performed with etch stop on the metal SD contact metal 303 and GAA metal 601. After stripping of photoresist, fill metal is deposited in the openings and CMP is performed to form SD connection 605 and GAA connection 607 as shown in
[0043]
[0044] Insulation and/or dielectric layers in the process of
[0045] The example embodiment of
[0046] Alternatively, other semiconductive materials may be used. Semiconductive materials herein may have properties similar to elemental semiconductor materials, and can be used to fabricate vertical stacks or planes of transistors. Note that given transistors within the vertical stacks can have channels with horizontal or vertical orientation relative to a working surface of the substrate. Certain materials, when combined with oxygen, may form new materials that exhibit semiconductor properties. For example, these semiconductor materials can turn “off” with low off-state leakage current or can become highly conductive under certain circumstances. In other words, such materials have an electrical conductivity value falling between an electrical conductor and an electrical insulator. Some examples of N-type semiconductive materials for channels include In.sub.2O.sub.3, SnO.sub.2, InGaZnO, and ZnO. One example of a P-type semiconductive material for channels is SnO. Thus, a “semiconductive oxide” herein is an oxygen-containing material having semiconductor properties.
[0047] In some embodiments, the dielectric core 301 may be replaced with a conductive oxide core. By using a 3D Mandrel or 3D Nano sheet Core made of either Oxide or an Oxide Semiconductor enables both semiconductive oxides channels and 2D channels and combinations to be realized for this disclosure. 2D Materials have greatly enhanced mobility relative to single crystal silicon. Conductive oxides may be used with both a solid core 3D Nano sheet core or an insulative core with a conductive oxide (semiconductive oxide) shell as options. Techniques herein enable all forms of growth and deposition of both 2D materials and conductive oxides. Embodiments can also include using a channel of both 2D Material and conductive oxide on the same 3D device. Techniques herein enable many 3D devices to be stacked n transistors tall. Replacing the dielectric core with conductive oxide enables different polarity conductive oxide to be matched with 2D channel polarity. The benefit of this structural design allows use of any dielectric, semiconductive or non-conductive as a channel core with little change to the fabrication process steps. Further, parallel conduction is provided with a 2D channel as well as conductive oxide channel.
[0048]
[0049]
[0050]
[0051] Additional tiers of transistors may be formed on the tier 1020 using similar process steps. For example, n-number of transistors in a stack may have the same or different 2D channel materials with a dielectric nanosheet core. Polarity of the 2D channels in a stack can be varied as p-type or n-type. Different High-k, gate metal, and SD metal can be used for different tiers of transistors, for example. Further, n number of transistor in a stack may have the same or different 2D channel materials with the same or different conductive oxide nanosheets. Polarity of the 2D transistors in the stack and semiconductive oxide may be paired for p-type or n-type transistors. Parallel channel vertical nanosheets of 2D and semiconductive oxide may also be provided in accordance with the teachings of this disclosure. As another example, n number of stacks of the same or different conductive oxide with the same dielectric nanosheet may be implemented. Still further, n number of transistors in a stack may have the same or different 2D channels with the same or different conductive oxide nanosheets on a dielectric core (this results in a conductive oxide channel shell over an insulative core 3D Nano Sheet)
[0052] Additional feature of techniques herein provide for using one unit cell to make both side-by-side and CFET (NMOS over PMOS) using just one unit cell. Techniques here enable high performance CMOS with very robust manufacturing because very few process steps are needed. Embodiments can have n devices tall with both CFET and side-by-side transistor architectures. Additional features include a metal first integration with all of embodiment flows.
[0053] In some embodiments, core structures may be recessed to provide for more area of connection of conductive oxide to metal.
[0054]
[0055] ALD deposition of conductive oxide is performed to cover the substrate followed by a directional etch of the conductive oxide to form the conductive oxide sidewall structure 1111. Similarly, ALD deposition of high-k material is performed to cover the substrate followed by a directional etch of the high-k material to form the high-k sidewall structure 1113. GAA structures 1115 are formed to complete the vertical transistors 1117 and transistor connections are formed as previously described herein.
[0056] In the preceding description, specific details have been set forth, such as a particular geometry of a processing system and descriptions of various components and processes used therein. It should be understood, however, that techniques herein may be practiced in other embodiments that depart from these specific details, and that such details are for purposes of explanation and not limitation. Embodiments disclosed herein have been described with reference to the accompanying drawings. Similarly, for purposes of explanation, specific numbers, materials, and configurations have been set forth in order to provide a thorough understanding. Nevertheless, embodiments may be practiced without such specific details. Components having substantially the same functional constructions are denoted by like reference characters, and thus any redundant descriptions may be omitted.
[0057] Of course, the order of discussion of the different steps as described herein has been presented for clarity sake. In general, these steps can be performed in any suitable order. Additionally, although each of the different features, techniques, configurations, etc. herein may be discussed in different places of this disclosure, it is intended that each of the concepts can be executed independently of each other or in combination with each other. Accordingly, the present disclosure can be embodied and viewed in many different ways.
[0058] Various techniques have been described as multiple discrete operations to assist in understanding the various embodiments. The order of description should not be construed as to imply that these operations are necessarily order dependent. Indeed, these operations need not be performed in the order of presentation. Operations described may be performed in a different order than the described embodiment. Various additional operations may be performed and/or described operations may be omitted in additional embodiments.
[0059] “Substrate” or “target substrate” as used herein generically refers to an object being processed in accordance with the invention. The substrate may include any material portion or structure of a device, particularly a semiconductor or other electronics device, and may, for example, be a base substrate structure, such as a semiconductor wafer, reticle, or a layer on or overlying a base substrate structure such as a thin film. Thus, substrate is not limited to any particular base structure, underlying layer or overlying layer, patterned or un-patterned, but rather, is contemplated to include any such layer or base structure, and any combination of layers and/or base structures. The description may reference particular types of substrates, but this is for illustrative purposes only.