WO2004019414A1 - Tri-gate devices and methods of fabrication - Google Patents
Tri-gate devices and methods of fabrication Download PDFInfo
- Publication number
- WO2004019414A1 WO2004019414A1 PCT/US2003/026242 US0326242W WO2004019414A1 WO 2004019414 A1 WO2004019414 A1 WO 2004019414A1 US 0326242 W US0326242 W US 0326242W WO 2004019414 A1 WO2004019414 A1 WO 2004019414A1
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- WIPO (PCT)
- Prior art keywords
- silicon
- gate
- transistor
- semiconductor
- laterally opposite
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- H01L29/772—Field effect transistors
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- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
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- H10K10/462—Insulated gate field-effect transistors [IGFETs]
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S977/00—Nanotechnology
- Y10S977/902—Specified use of nanostructure
- Y10S977/932—Specified use of nanostructure for electronic or optoelectronic application
- Y10S977/936—Specified use of nanostructure for electronic or optoelectronic application in a transistor or 3-terminal device
- Y10S977/938—Field effect transistors, FETS, with nanowire- or nanotube-channel region
Definitions
- the present invention relates to the field of semiconductor integrated circuit manufacturing, and more particularly to a tri-gate fully depleted substrate transistor and its methods of fabrication.
- the need for ever decreasing silicon film thickness (Tsi) makes this approach increasingly impractical.
- the thickness required of the silicon body is thought to need to be less than 10 nanometers, and around 6 nanometer for a 20 nanometer gate length. The fabrication of thin silicon films with thicknesses of less than 10 nanometers, is considered to be extremely difficult.
- a double gate (DG) device such as shown in Figures 2A and 2B, have been proposed to alleviate the silicon thickness issue.
- the double gate (DG) device 200 includes a silicon body 202 formed on an insulating substrate 204.
- a gate dielectric 206 is formed on two sides of the silicon body 202 and a gate electrode 208 is formed adjacent to the gate dielectric 206 formed on the two sides of the silicon body 202.
- the most manufacturable form of the double gate (DG) device 200 requires that the body 202 patterning be done with photolithography that is 0.7 x smaller than that used to pattern the gate length (Lg) of the device.
- Figures 2A and Figure 2B illustrate a double gate depleted substrate transistor.
- Figure 3 is an illustration of a tri-gate transistor in accordance with an embodiment of the present invention.
- Figure 4A is an illustration of a tri-gate transistor in accordance with an embodiment of the present invention.
- Figure 4B is an illustration of a tri-gate transistor in accordance with an embodiment of the present invention.
- Figures 5A-5J illustrate methods of fabricating a tri-gate transistor in accordance with embodiments of the present invention.
- the present invention is a novel tri-gate transistor structure and its method of fabrication.
- numerous specific details are set forth in order to provide a thorough understanding in the present invention.
- well-known semiconductor process and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the present invention.
- the semiconductor body can be fully depleted when the transistor is turned "ON", thereby enabling the formation of a fully depleted transistor with gate lengths of less than 30 nanometers without requiring the use of ultra-thin semiconductor bodies or requiring photolithographic patterning of the semiconductor bodies to dimensions less than the gate length (Lg) of the device. That is, the structure of the tri-gate transistor of the present invention enables a fully depleted transistor to be fabricated where the thickness of the semiconductor body and width of the semiconductor body are equal to the gate length of the device.
- the novel tri-gate transistor of the present invention can be operated in a fully depleted manner, the device is characterized by ideal (i.e., very sharp) subthreshold slope and a reduced drain induced barrier lowering (DIBL) short channel effect of less than lOOmV/N and ideally about 60 mV/V which results in a lower leakage current when the device is turned “OFF” resulting in lower power consumption.
- DIBL drain induced barrier lowering
- Tri-gate transistor 300 includes a semiconductor body 308 formed on insulator 306 of insulating substrate 302.
- Semiconductor body 308 can be formed of any well-known semiconductor material, such as but not limited to silicon (Si), germanium (Ge), silicon germanium (Si x Ge y ), gallium arsenide (GaAs), InSb, GaP, GaSb and carbon nanotubes.
- Semiconductor body 308 can be formed of any well-known material which can be reversibly altered from an insulating state to a conductive state by applying external electrical controls.
- Semiconductor body 308 is ideally a single crystalline film when the best electrical performance of transistor 300, is desired.
- semiconductor body 308 is a single crystalline film when transistor 300 is used in high performance applications, such as in a high density circuit, such as a microprocessor.
- Insulator 306 insulates semiconductor body 308 from monocrystalline silicon substrate 302.
- semiconductor body 308 is a single crystalline silicon film.
- Semiconductor body 308 has a pair of laterally opposite sidewalls 310 and 312 separated by a distance which defines a semiconductor body width 314. Additionally, semiconductor body 308 has a top surface 316 opposite a bottom surface 318 formed on substrate 302.
- Tri-gate transistor 300 has a gate dielectric layer 322.
- Gate dielectric layer 322 is formed on and around three sides of semiconductor body 308 as shown in Figure 3.
- Gate dielectric layer 322 is formed on or adjacent to sidewall 312, on top surface 316 and on or adjacent to sidewall 310 of body 308 as shown in Figure 3.
- Gate dielectric layer 322 can be any well-known gate dielectric layer.
- the gate dielectric layer is a silicon dioxide (Si ⁇ 2), silicon oxynitride (SiO x N y ) or a silicon nitride dielectric layer.
- the gate dielectric layer 322 is a silicon oxynitride film formed to a thickness of between 5-20A.
- gate dielectric layer 322 is a high K gate dielectric layer, such as a metal oxide dielectric, such as but not limited to tantalum pentaoxide (Ta2 ⁇ s), and titantium oxide (Ti ⁇ 2).
- Gate dielectric layer 322 can be other types of high K dielectric, such as but not limited to PZT.
- Tri-gate device 300 has a gate electrode 324.
- Gate electrode 324 is formed on and around gate dielectric layer 322 as shown in Figure 3.
- Gate electrode 324 is formed on or adjacent to gate dielectric 322 formed on sidewall 312 of semiconductor body 308, is formed on gate dielectric 322 formed on the top surface 316 of semiconductor body 308, and is formed adjacent to or on gate dielectric layer 322 formed on sidewall 310 of semiconductor body 308.
- Gate electrode 324 has a pair of laterally opposite sidewalls 326 and 328 separated by a distance which defines the gate length (Lg) 330 of transistor 300.
- gate electrode 324 can be formed of any suitable gate electrode material. In an embodiment of the present invention to gate electrode 324 comprises of polycrystalline
- the doping concentration and profile of the source region 330 and the drain region 332 may vary in order to obtain a particular electrical characteristic.
- the channel region 350 can also be defined as the area of the semiconductor body 308 surrounded by the gate electrode 324.
- the source/drain region may extend slightly beneath the gate electrode through, for example, diffusion to define a channel region slightly smaller than the gate electrode length (Lg).
- channel region 350 is intrinsic or undoped monocrystalline silicon, hi an embodiment of the present invention, channel region 350 is doped monocrystalline silicon.
- channel region 350 When channel region 350 is doped it is typically doped to a conductivity level of between lxlO 16 to lxlO 19 atoms/cm .
- the channel region when the channel region is doped it is typically doped to the opposite conductivity type of the source region 330 and the drain region 332.
- the source and drain regions are N-type conductivity the channel region would be doped to p type conductivity.
- the source and drain regions are P type conductivity the channel region would be N-type conductivity.
- a tri-gate transistor 300 can be formed into either a NMOS transistor or a PMOS transistor respectively.
- the gate “width” (Gw) of transistor 300 is the sum of the widths of the three channel regions. That is, the gate width of transistor 300 is equal to the height 320 of silicon body 308 at sidewall 310, plus the width of silicon body of 308 at the top surface 316, plus the height 320 of silicon body 308 at sidewall 312. Larger “width” transistors can be obtained by using multiple devices coupled together (e.g., multiple silicon bodies 308 surrounded by a single gate electrode 324).
- the tri-gate transistor of the present invention can be said to be a nonplanar transistor because the channel regions are formed in both the horizontal and verticle directions in semiconductor body 308.
- the depletion region depletes free carriers from beneath the inversion layers.
- the depletion region extends to the bottom of channel region 350, thus the transistor can be said to be a "fully depleted" transistor.
- Fully depleted transistors have improved electrical performance characteristics over non-fuUy depleted or partially depleted transistors. For example, by operating transistor 300 in the fully depleted manner, gives transistor 300 an ideal or very steep subthreshold slope.
- the tri-gate transistor can be fabricated with very steep sub-threshold slope of less than 80 mV/decade, and ideally about 60 mV/decade even when fabricated with semiconductor body thicknesses of less than 30 nm. Additionally, operating transistor 300 in the fully depleted manner, transistor 300 has an improved drain induced barrier (DIBL) low in effect which provides for better "OFF" state leakage which results in lower leakage and thereby lower power consumption. In an embodiment of the present invention the tri-gate transistor 300 has a DIBL effect of less than lOOmV/V and ideally less than 40 mV/V.
- DIBL drain induced barrier
- Figure 6 is an illustration of two plots 602 and 604 which set forth the body height and body width which will produce either fully depleted (F.D) or partially depleted (P.D) tri-gate transistors having gate length (Lg) of 30 nm (602) and 20 nm (604) respectively.
- the body height, body width and gate length are chosen to have dimensions in which a fully depleted transistor will be formed.
- the tri-gate transistor has a body height, body width and gate length such that a partially depleted transistor is formed.
- the source and drain regions can include a silicon or other semiconductor film 410 formed on and around semiconductor body 308 as shown in Figure 4 A.
- semiconductor film 410 can be a silicon film or a silicon alloy such as silicon germanium (Si x Ge y ).
- the semiconductor film 410 is a single crystalline silicon film formed of the same conductivity type as the source region 330 and drain region 332.
- the semiconductor film can be a silicon alloy such as silicon germanium wherein silicon comprises approximately 1 to 99 atomic percent of the alloy.
- the semiconductor film 410 need not necessarily be a single crystalline semiconductor film and in an embodiment can be a polycrystalline film.
- the semiconductor film 410 is formed on the source region 330 and on the drain region 332 of semiconductor body 308 to form "raised" source and drain regions.
- Semiconductor film 410 can be electrically isolated from a gate electrode 324 by a pair of dielectric sidewall spacers 420 such as silicon nitride or silicon oxide or composites thereof.
- Sidewall spacers 420 run along the laterally opposite sidewalls 326 and 328 of gate electrode 324 as shown in Figure 4A thereby isolating the semiconductor film 410 from gate electrode 324 as shown in Figure 4A.
- An embodiment of the present invention sidewalls spacers 420 have a thickness of between 20-200A.
- the thickness of the source and drain regions is increased thereby reducing the source/drain contact resistance to transistor 300 and improving its electrical characteristics and performance.
- a silicide film 430 such as, but not limited to, titanium silicide, nickel silicide, and cobalt silicide is formed on the source region 330 and drain region 332.
- silicide film 430 is formed on a silicon film 410 of silicon body 308 as shown in Figure 4A. Silicide film 430 however can also be formed directly onto the top surface 316 of silicon body 308.
- silicide film 430 can be formed on silicon body 308 by first forming a silicon film such as an undoped silicon film and a silicon body and then completely consuming the silicon film during the silicide process.
- Dielectric spacers 420 enables silicide film 430 to be formed on semiconductor body 308 or silicon film 410 in a self-aligned process (i.e., a salicide process).
- transistor 300 can include an additional or multiple semiconductor bodies or fingers 308 as shown in Figure 4B.
- Each semiconductor body 308 has a gate dielectric layer 322 formed on its top surface and sidewalls as shown in Figure 4B.
- Gate electrode 324 is formed on and adjacent to each gate dielectric 322 on each of the semiconductor bodies 308.
- Each semiconductor body 308 also includes a source region 330 and a drain region 332 formed in the semiconductor body 308 on opposite sides of gate electrode 324 as shown in Figure'4B.
- each semiconductor body 308 is formed with the same width and height (thickness) as the other semiconductor bodies 308.
- each source regions 330 and drain regions 332 of the semiconductor bodies 308 are electrically coupled together by the semiconductor material used to form semiconductor body 308 to form a source landing pad 460 and a drain landing pad 480 as shown in Figure 4B.
- the source regions 330 and drain regions 332 can be coupled together by higher levels of metalization (e.g., metal 1 , metal 2, metal 3...) used to electrically interconnect various transistors 300 together into functional circuits.
- the gate width of transistor 300 as shown in Figure 4B would be equal to the sum of the gate width created by each of the semiconductor bodies 308. In this way, the tri-gate transistor 300 can be formed with any gate width desired.
- FIG. 5A-5 J A method of fabricating a tri-gate transistor in accordance with embodiments of the present invention is illustrated in Figures 5A-5 J.
- the fabrication of a tri-gate transistor begins with substrate 502.
- a silicon or semiconductor film 508 is formed on substrate 502 as shown in Figure 5 A.
- the substrate 502 is an insulating substrate, such as shown in Figure 5 A.
- insulating substrate 502 includes a lower monocrystalline silicon substrate 504 and a top insulating layer 506, such as a silicon dioxide film or silicon nitride film.
- Insulating layer 506 isolates semiconductor film 508 from substrate 504, and in embodiment is formed to a thickness between 200-2000A. Insulating layer 506 is sometimes referred to as a "buried oxide" layer.
- the substrate 502 can be a semiconductor substrate, such as but not limited to a silicon monocrystalline substrate and a gallium arsenide substrate.
- semiconductor film 508 is ideally a silicon film, in other embodiments it can be other types of semiconductor films, such as but not limited to germanium (Ge), a silicon germanium alloy (Si x Ge y ), gallium arsenide (GaAs), InSb, GaP, GaSb, as well as carbon nanotubes.
- semiconductor film 508 is an intrinsic (i.e., undoped) silicon film.
- semiconductor film 508 is doped to a p type or n type conductivity with a concentration level between 1x10 -1x10
- Semiconductor film 508 can be insitu doped (i.e., doped while it is deposited) or doped after it is formed on substrate 502 by for example ion-implantation. Doping after formation enables both PMOS and NMOS tri-gate devices to be fabricated easily on the same insulating substrate. The doping level of the semiconductor body at this point determines the doping level of the channel region of the device.
- Semiconductor film 508 is formed to a thickness which is approximately equal to the height desired for the subsequently formed semiconductor body or bodies of the fabricated tri-gate transistor. In an embodiment of the present invention, semiconductor film 508 has a thickness or height 509 of less than 30 nanometers and ideally less than 20 nanometers. In an embodiment of the present invention, semiconductor film 508 is formed to the thickness approximately equal to the gate "length" desired of the fabricated tri-gate transistor. In an embodiment of the present invention, semiconductor film 508 is formed thicker than desired gate length of the device. In an embodiment of the present invention, semiconductor film 580 is formed to a thickness which will enable the fabricated tri-gate transistor to be operated in a fully depleted manner for its designed gate length (Lg).
- Lg gate length
- a high dose hydrogen implant is made into the first silicon wafer to form a high stress region below the silicon surface of the first wafer.
- This first wafer is then flipped over and bonded to the surface of a second silicon wafer.
- the first wafer is then cleaved along the high stress plain created by the hydrogen implant. This results in a SOI structure with a thin silicon layer on top, the buried oxide underneath all on top of the single crystalline silicon substrate.
- Well-known smoothing techniques such as HC smoothing or chemical mechanical polishing (CMP) can be used to smooth the top surface of semiconductor film 508 to its desired thickness.
- isolation regions can be formed into SOI substrate 500 in order to isolate the various transistors to be formed therein from one another. Isolation regions can be formed by etching away portions of the substrate film 508 surrounding a tri-gate transistor, by for example well-known photolithographic and etching techniques, and then back filling the etched regions with an insulating film, such as SiO 2 .
- a photoresist mask 510 is formed on semiconductor film 508 as shown in Figure 5B.
- the photoresist mask 510 contains a pattern or plurality of patterns 512 defining locations where semiconductor bodies or fins will be subsequently formed in the semiconductor film 508.
- the photoresist pattern 512 defines the width 518 desired of the subsequently formed semiconductor bodies or fins of the tri-gate transistor.
- the pattern 512 define fins or bodies having a width 518 which is equal to or greater than the width desired of the gate length (Lg) of the fabricated transistor.
- the semiconductor bodies or fins will have a width 518 less than or equal to 30 nanometers and ideally less than or equal to 20 nanometers, hi an embodiment of the present invention, the patterns 512 for the semiconductor bodies or fins have a width 518 approximately equal to the silicon body height 509.
- the photoresist patterns 512 have a width 518 which is between l ⁇ the semiconductor body height 509 and two times the semiconductor body height 509.
- the photoresist mask 510 can also include patterns 514 and 516 for defining locations where source landing pads and drain landing pads, respectively, are to be formed.
- the landing pads can be used to connect together the various source regions and to connect together the various drain regions of the fabricated transistor.
- the photoresist mask 510 can be formed by well-known photolithographic techniques including masking, exposing, and developing a blanket deposited photoresist film. After forming photoresist mask 510, semiconductor film 508 is etched in alignment with photoresist mask 510 to form one or more silicon bodies or fins and source and drain landing pads (if desired) as shown in Figure 5C. Semiconductor film 508 is etched until the underlying buried oxide layer 506 is exposed. Well-known semiconductor etching techniques, such as anisotropic plasma etching or reactive ion etching can be used to etch semiconductor film 508 in alignment with mask 510 as shown in Figure 5C.
- a gate dielectric layer 526 is formed on the top surface 527 of each of the semiconductor bodies 520 as well as on the laterally opposite sidewalls 528 and 529 of each of the semiconductor bodies 520.
- the gate dielectric can be a deposited dielectric or a grown dielectric.
- the gate dielectric layer 526 is a silicon dioxide dielectric film grown with a dry/wet oxidation process.
- the silicon oxide film is grown to a thickness of between 5-15A.
- the gate electrode can be formed to a thickness 533 between 200-3000A. In an embodiment the gate electrode has a thickness or height 533 of at least three times the height 509 of semiconductor bodies 520.
- the gate electrode material is then patterned with well-known photolithography and etching techniques to form gate electrode 530 from the gate electrode material.
- the gate electrode material comprises polycrystalline silicon.
- the gate electrode material comprises a polycrystalline silicon germanium alloy.
- the gate electrode material can comprise a metal film, such as tungsten, tantalum, and their nitrides.
- Gate electrode 530 can be formed by well-known techniques, such as by blanket depositing a gate electrode material over the substrate of Figure 5D and then patterning the gate electrode material with well-known photolithography and etching techniques.
- the photolithography process used to define gate electrode 530 utilizes the minimum or smallest dimension lithography process used to fabricate the tri-gate transistor. (That is, in an embodiment of the present invention, the gate length (Lg) 538 of gate electrode 530 has a minimum feature dimension of the transistor defined by photolithography.)
- the gate length 538 is less than or equal to 30 nanometers and ideally less than or equal to 20 nanometers.
- source and drain regions for the transistor are formed in semiconductor body 520 on opposite sides of gate electrode 530.
- the source and drain regions include tip or source/drain extension regions.
- Source and drain extension regions 540 and 542, respectively, can be formed by placing dopants 544 into semiconductor bodies 520 on both sides 532, 534 of gate electrode 530 in order to form tip regions 540 and 542 as shown in Figure 5F.
- Source and drain landing pads 522 and 524 are not shown in Figures 5F-5 J to better illustrate aspects of the present invention. If source and drain landing pads 522 and 524 are utilized, they may be doped at this time also.
- the semiconductor fins or bodies 520 are doped to a p
- the semiconductor fins or bodies 520 is doped with n type
- the silicon films are doped by ion-implantation.
- the ion-implantation occurs in a vertical direction (i.e., a direction perpendicular to substrate 500) as shown in Figure 5F.
- gate electrode 530 is a polysilicon gate electrode, it can be doped during the ion-implantation process. Gate electrode 530 acts as a mask to prevent the ion-implantation step from doping the channel region(s) 548 of the tri-gate transistor.
- the channel region 548 is the portion of the silicon body 520 located beneath or surrounded by the gate electrode 530.
- a dielectric hard mask maybe used to block the doping during the ion-implantation process.
- other methods such as solid source diffusion, may be used to dope the semiconductor body to form source and drain extensions.
- halo regions can be formed in silicon body prior to the formation of a source/drain regions or source/drain extension regions.
- Halo regions are doped regions formed in the channel region 548 of the device and are of the same conductivity but of a slightly higher concentration than the doping of the channel region of the device.
- Halo regions can be formed by ion-implantating dopants beneath the gate electrode by utilizing large angled ion-implantation techniques.
- the substrate shown in Figure 5F can be further processed to form additional features, such as heavily doped source/drain contact regions, deposited silicon on the source and drain regions as well as the gate electrode, and the formation of silicide on the source/drain contact regions as well as on the gate electrode.
- dielectric sidewall spacers 550 can be formed on the sidewalls of the gate electrode. Sidewall spacers can be utilized to offset heavy source/drain contact implants, can be used to isolate source/drain regions from the gate electrode during a selective silicon deposition processes and can be used in a salicide process to form silicide on the source and drain regions as well as on the gate electrode.
- the dielectric film is anisotropically etched by for example plasma etching or reactive ion etching to form sidewall spacers 550.
- the anisotropic etch of dielectric film removes the dielectric film from horizontal surfaces, such as the top of gate electrode 530 (as well as the top of landing pads 522 and 524 if used) and leaves dielectric sidewall spacers adjacent to vertical surfaces, such as sidewalls 534 and 536 of gate electrode 530.
- the etch is continued for a sufficient period of time to remove the dielectric film from all horizontal surfaces.
- an over etch is utilized so that the spacer material on the sidewalls of the semiconductor bodies 520 is removed as shown in Figure 5G.
- the result is the formation of sidewall spacers 550 which run along and adjacent to sidewall 532 and 534 of gate electrode 530 as shown in Figure 5H.
- a semiconductor film 560 can be formed on the exposed surfaces of semiconductor body 520 (as well as on landing pads 522 and 524) as shown in Figure 5H. Additionally, if desired, a semiconductor film 562 can be formed on the top of gate electrode 530.
- the semiconductor film can be a single crystalline film or a polycrystalline film.
- semiconductor film 560 is an epitaxial (single crystalline) silicon film.
- the silicon film 560 is formed by a selective deposition process whereby silicon is formed only on exposed regions which contain silicon, such as the exposed top surface 527 and sidewalls 528 and 529 of silicon body 520.
- the silicon film is doped to the conductivity type desired for the source and drain regions of the device.
- the deposited silicon film 560 and 562 are intrinsic silicon films (i.e., undoped silicon films).
- the deposition of semiconductor film 560 forms raised source and drain regions which ' improves the parasitics of the device.
- the deposited silicon film 560 and 562 are doped by ion-implantation utilizing a vertical ion- implantation angle. The ion-implantation process dopes the deposited silicon film 560 and
- a refractory metal silicide 580 can be formed on the source and drain contact regions as well as on the top of gate electrode 530 (or silicon film 562) as shown in Figure 5J.
- a refractory metal silicide film 580 can be formed with a self-aligned process, such as a salicide process.
- a refractory metal film such as titanium, tungsten, nickel, cobalt or alike to blanket deposited over the substrate of Figure 5 J.
- the substrate is then heated to a suitable temperature to cause the refractory metal film to react with silicon portion of substrate 500, such as silicon film 560 formed on the silicon bodies and silicon film 562 formed on the gate electrodes in order to form a refractory metal silicide.
Abstract
Description
Claims
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EP03788707A EP1425801A1 (en) | 2002-08-22 | 2003-08-22 | Tri-gate devices and methods of fabrication |
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AU2003262770A AU2003262770A1 (en) | 2002-08-23 | 2003-08-22 | Tri-gate devices and methods of fabrication |
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