US20170179248A1 - Horizontal gate all around nanowire transistor bottom isolation - Google Patents
Horizontal gate all around nanowire transistor bottom isolation Download PDFInfo
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- US20170179248A1 US20170179248A1 US14/970,661 US201514970661A US2017179248A1 US 20170179248 A1 US20170179248 A1 US 20170179248A1 US 201514970661 A US201514970661 A US 201514970661A US 2017179248 A1 US2017179248 A1 US 2017179248A1
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Definitions
- the present invention relates to semiconductor devices and methods of fabricating the same. More specifically, the invention relates to various methods of forming nanowire channels in gate-all-around (GAA) MOSFETs.
- GAA gate-all-around
- MOSFETs planar metal-oxide-semiconductor field effect transistors
- Fin field effect transistors have exhibited improved control over a planar gate MOSFET design by wrapping the gate electrode over three sides of a fin-shaped channel.
- GAA MOSFETs are similar to FinFETs but have the potential of even greater electrostatic control over the channel because the gate electrode completely surrounds the channel.
- the channel region is essentially a nanowire.
- the nanowire channel typically has a thickness (or diameter) in the tens of nanometers (nm) or less and has an unconstrained length.
- the nanowire channel is suspended generally horizontally between, and anchored to, the much larger source and drain regions of the GAA MOSFET.
- GAA MOSFETs can be fabricated on a bulk silicon substrate utilizing fully compatible CMOS technology.
- a typical manufacturing method of forming the channel regions in a GAA MOSFET involves epitaxially growing a stack (epi-stack) of sacrificial layers sandwiched between channel layers on top of a bulk substrate.
- the sacrificial layers and channel layers are composed of two different materials so that selective etching can remove the sacrificial layers.
- an epi-stack can be formed of alternating silicon (Si) and silicon germanium (SiGe) layers, wherein the Si layers are the sacrificial layers and the SiGe layers are the channel layers.
- the Si layers can then be removed by selective etching (for example via a wet etching process such as a TMAH), which also inadvertently recesses trenches into the bulk substrate due to the similarity of materials composing the sacrificial layers and the substrate.
- the SiGe layers can subsequently be formed into the nanowire channels suspended over the trenches.
- a thin gate dielectric is then disposed around the SiGe nanowire channels and over the recessed trenches of the substrate. Metal is then disposed over the dielectric to form the metal gate electrode of the GAA MOSFET.
- the present invention offers advantages and alternatives over the prior art by providing a GAA MOSFET and methods of making the same, wherein the MOSFET includes an etch stop-electric well (ESEW) layer disposed over a substrate.
- ESEW etch stop-electric well
- the ESEW layer functions as an etch stop barrier to prevent etching of trenches in the substrate during an etching removal process of any sacrificial layers when making the MOSFET.
- the ESEW layer additionally provides an electric barrier against potential shorts across the gate dielectric by providing an additional p-n or n-p barrier at the common boundary between ESEW layer and substrate.
- a method of making a GAA MOSFET in accordance with one or more aspects of the present invention includes providing a substrate having source, drain and channel regions for a GAA MOSFET, the substrate being doped with one of a p-type and an n-type dopant.
- An etch stop-electric well (ESEW) layer is then disposed over the substrate, the ESEW layer is doped with the other of the p-type and the n-type dopant.
- a sacrificial layer is disposed over the ESEW layer, the sacrificial layer is doped with the same type dopant as the substrate.
- a channel layer is disposed over the sacrificial layer.
- the method further includes patterning a fin out of the ESEW layer, sacrificial layer, and channel layer in the channel region. Additionally the method includes selectively etching away only the sacrificial layer of the fin to form a nanowire from the channel layer of the fin while the ESEW layer of the fin functions as an etch stop barrier to prevent etching of trenches in the substrate.
- a GAA MOSFET in another exemplary embodiment of the invention, includes a substrate doped with one of an n-type and a p-type dopant.
- An etch stop-electric well (ESEW) layer is disposed over the substrate.
- the ESEW layer is doped with the other of the n-type and p-type dopant and is composed of a different material than the substrate.
- the GAA MOSFET also includes a source, drain and channel region disposed over the ESEW layer, the channel region having a nanowire channel connected between the source and drain regions.
- a gate dielectric coating is disposed over the nanowire channel and the ESEW layer in the channel region.
- a gate metal is disposed over the gate dielectric coating in the channel region to form a gate electrode of the GAA MOSFET.
- the ESEW layer is free of any trenches under the nanowire channel.
- FIG. 1 is perspective view of an exemplary prior art GAA MOSFET structure
- FIG. 2A is a perspective view of the prior art GAA MOSFET structure of FIG. 1 at an intermediate stage of manufacturing
- FIG. 2B is a cross sectional view of prior art FIG. 2A taken along the sectional line 2 B- 2 B;
- FIG. 3 is the cross sectional view of prior art FIG. 2B further patterned in the channel region to form a pair of fins;
- FIG. 4 is the cross sectional view of prior art FIG. 3 after selective removal of sacrificial layers
- FIG. 5 is the cross sectional view of the channel region of the completed prior art GAA MOSFET structure
- FIG. 6 is a cross sectional view of a GAA MOSFET structure at an intermediate stage of manufacturing in accordance with the present invention.
- FIG. 7 is a cross sectional view of FIG. 6 further patterned in the channel region to form a pair of fins in accordance with the present invention
- FIG. 8A is a cross sectional view of FIG. 7 after selective removal of sacrificial layers in accordance with the present invention.
- FIG. 8B is a cross sectional view of GAA MOSFET structure 100 taken along sectional line 8 B- 8 B of FIG. 8A ;
- FIG. 9 is a cross sectional view of the channel region of the completed GAA MOSFET structure in accordance with the present invention.
- FIGS. 1-5 illustrate various exemplary embodiments of a prior art GAA MOSFET and methods of making the same.
- GAA MOSFET 10 includes a source region 12 , a drain region 14 and a channel region 16 embedded in a substrate 18 .
- the source 12 and drain 14 regions are shown as planar in shape, but can be other shapes as well, such as in the form of a fin to make the MOSFET 10 essentially a FinFET.
- the channel region 16 includes a pair of nanowire channels 20 extending horizontally relative to a top planar surface 22 of the substrate 18 .
- the gate dielectric and all-around gate electrode, which surround the nanowire channels 20 are not shown. The gate electrode is operable to control electric conduction through the nanowire channels 20 from source 12 to drain 14 as is well known.
- nanowire channels 20 any number of such channels may be included in the channel region 16 .
- the nanowire channels may be oriented in a row (as is shown) extending horizontally across the planar surface 22 of the substrate 18 , or stacked vertically in columns extending vertically normal to the planar surface 22 .
- the source 12 , drain 14 and nanowire channels 16 are typically patterned from an alternating plurality of epitaxially grown sacrificial layers 24 and channel layers 26 disposed over the surface 22 of the substrate 18 .
- the sacrificial layer 24 is removed, generally by a wet etch process such as with a tetra-methyl ammonium hydroxide (TMAH) solution, in the channel region 16 .
- TMAH tetra-methyl ammonium hydroxide
- this embodiment only shows one sacrificial layer 24 and one channel layer 26 , but any number of such pairs may be utilized to form a stacked column of any number of nanowire channels 20 .
- FIG. 2A a simplified perspective view of the prior art GAA MOSFET structure 10 of FIG. 1 at an intermediate stage of manufacturing is presented.
- FIG. 2B a cross sectional view of FIG. 2A taken along the sectional line 2 B- 2 B is also presented.
- the sacrificial layer 24 and channel layer 26 have been epitaxially grown over substrate 18 to form an epi-stack.
- the two layers 24 , 26 must be of different materials since one layer (i.e., the sacrificial layer 24 ) will be selectively removed by selective etching.
- the substrate 18 is silicon (Si)
- the sacrificial layer 24 is also Si
- the channel layer 26 is silicon germanium (SiGe).
- the source region 12 , the drain region 14 and the channel region 16 include only unpatterned portions of the epitaxially grown Si sacrificial layer 24 disposed over the Si substrate 18 , and the epitaxially grown SiGe channel layer 26 disposed over the sacrificial layer.
- the cross sectional view in FIG. 2B is taken through the channel region 16 .
- the GAA MOSFET structure 10 has been further patterned in the channel region 16 to form a pair of fins 28 out of the SiGe channel layer 26 , the Si sacrificial layer 24 and a portion of substrate 18 .
- One or more dielectric materials (such as silicon dioxide) are deposited in trenches and polished down to the top surface 22 of the substrate 18 to form a plurality of shallow trench isolation (STI) layers 30 .
- the STI layers 30 extend along the length of the fins 28 to prevent current leakage between the nanowire channels that are to be formed in the fins.
- a wet etching process (such as TMAH etching) is utilized to selectively remove the remainder of the sacrificial layer 24 from under the portion of channel layer 26 that is in the channel region 16 .
- the now suspended portions of the channel layer 26 in the channel region 16 function as the nanowire channels 20 (best seen FIG. 1 ).
- the etching process inadvertently recesses trenches 32 into the substrate 18 .
- This uncontrolled etching process forms rough irregular bottoms to the trenches 32 , which varies from trench to trench and can detrimentally affect device performance.
- a gate dielectric 34 is disposed entirely around the nanowire channels 20 , over the STI layers 30 , and over trenches 30 recessed in substrate 18 .
- the gate dielectric is preferably a high-k dielectric (with a high dielectric constant as compared to silicon dioxide). Examples of high-k dielectrics are hafnium silicate, zirconium silicate, hafnium dioxide, zirconium dioxide and the like.
- the high-k dielectric material is typically deposited using an atomic layer deposition process.
- a gate metal is next disposed around the entirety of the dielectric 34 covered channels 20 and over the dielectric 34 covered STI layer 30 and substrate 18 to form the gate electrode 36 and complete the GAA MOSFET structure 10 .
- the gate metal may be such metals as Tantalum (Ta), Tantalum Nitride (TaN), Niobium (Nb), Tungsten Nitride, Ruthenium Oxide and the like.
- the deposition process in the area of the trenches 32 under the channels 20 is difficult to complete and irregular voids 38 are often formed.
- the gate dielectric is very thin and sometimes does not adequately isolate the gate electrode 36 from the substrate 18 . This is especially problematic at the rough bottoms of the trenches 32 , where uniform deposition of the dielectric coating 34 is difficult to control. As a result, the potential for electrical shorts to occur across the dielectric 34 from gate 36 to substrate 18 is higher within the irregular shaped trenches 32 .
- FIGS. 6-9 illustrate various exemplary embodiments of a GAA MOSFET and methods of making the same in accordance with the present invention.
- FIG. 6 a cross sectional view of a GAA MOSFET structure 100 at an intermediate stage of manufacturing in accordance with the present invention is presented.
- FIG. 6 is analogous to prior art FIG. 2B in that both illustrate cross sections through channel regions of their respective GAA MOSFETs after epitaxially grown layers have been disposed on the surface of a substrate and prior to fin formation.
- the GAA MOSFET structure 100 has a source region 102 (best seen in FIG. 8B ) and a drain region 104 (best seen in FIG. 8B ) interconnected by a channel region 106 .
- the channel region 106 includes a silicon substrate 108 , which, for this particular exemplary embodiment, is doped with an n-type dopant, such as phosphorus, arsenic or the like, to provide an n-type semiconductor material.
- the substrate 108 could also have been doped with a p-type dopant, such as boron, gallium or the like.
- the substrate 108 could also have been of a material other than Si, such as germanium (Ge), silicon germanium (SiGe) or the like.
- an etch stop-electric well (ESEW) layer 110 is disposed over the surface of the substrate 108 .
- ESEW layer 110 is doped with a p-type dopant since the substrate 108 is doped n-type. That is, if the substrate 108 is be doped with one of an n-type and a p-type dopant, then the ESEW layer 110 will be doped with the other of the n-type and p-type dopant. In this way, an n-p junction or a p-n junction is formed at the common boundary 112 between the substrate 108 and the ESEW layer 110 .
- the n-p junction (or n-p junction) induces a depletion region which functions as an electric voltage barrier (or electric well) to any leakage current from ESEW layer 110 to substrate 108 .
- the ESEW layer 110 is also composed of a different material than the substrate 108 .
- the substrate 108 is Si and the ESEW layer is composed of SiGe. This is done so that the ESEW layer 110 not only functions as an electric well opposing current leakage to the substrate 108 , but also advantageously functions as an etch stop that protects the substrate during any selective etching process of structure 100 .
- SiGe was selected as the material composition for the ESEW layer 110 , one skilled in the art would recognize that many other materials can be used. However, the material for the ESEW layer 110 should be different enough from the material of the substrate 108 such that the ESEW layer will not readily etch, or preferably not etch at all, during an etching process that would readily etch the substrate.
- a sacrificial layer 114 is disposed over the top surface of the ESEW layer 110 .
- Sacrificial layer 114 is typically composed of a very similar material to that of the substrate 108 , and, therefore, is composed of a very different material to that of the ESEW layer 110 .
- the sacrificial layer 114 is composed of Si, the exact same material as the substrate 108 .
- the sacrificial layer 108 can be removed through selective etching, such as wet etching, while the ESEW layer 110 functions as an etch stop during the etching process.
- the sacrificial layer 114 is also doped with the same type dopant as the substrate 108 .
- both the sacrificial layer 114 and substrate 108 are doped with an n-type dopant.
- an additional n-p junction is set up at the common boundary 116 between sacrificial layer 114 and the ESEW layer 110 .
- additional electric well or electric voltage barrier
- the common boundaries 116 and 112 between the sacrificial layer 114 , the ESEW layer 110 and the substrate 108 collectively form an n-p-n junction, which strongly resists leakage current or potential shorts to the substrate 108 .
- the ESEW layer 114 would necessarily be doped with an n-type dopant and the sacrificial layer would also necessarily be doped with a p-type dopant.
- a p-n junction would be induced at boundary 116
- a p-n-p junction would be induced collectively across boundaries 116 and 112 .
- a channel layer 118 is disposed over the sacrificial layer 114 .
- channel layer 118 is composed of SiGe, which is the same material as the ESEW layer 110 .
- a second sacrificial layer 120 Disposed over the channel layer 118 is a second sacrificial layer 120 composed of Si, and disposed over the second sacrificial layer 120 is a second channel layer 122 composed of SiGe.
- this embodiment shows two epitaxially grown sacrificial layers 114 and 120 alternating between two epitaxially grown channel layers 118 and 122 , one skilled in the art would recognize that any plurality of alternating sacrificial layers and channel layers may be disposed over the ESEW layer. What is highly preferable is that the sacrificial layers be of the same material composition, and the channel layers be of the same material composition. Additionally, the sacrificial layers must be composed of a different material than that of the channel layers in order to be able to selectively etch away the sacrificial layers while leaving the channel layer intact.
- the GAA MOSFET 100 has been further patterned in the channel region 106 to form a pair of fins 124 out of the channel layers 122 and 118 , the sacrificial layer 120 and 114 , the ESEW layer 110 and a portion of the substrate 108 . Additionally a plurality of STI layers 126 have been disposed between the fins 124 to prevent current leakage there between. Though two fins 124 have been patterned in this embodiment, one skilled in the art would recognize that any plurality of fins may be patterned in the channel region 106 .
- a wet etch process is utilized to selectively remove the remainder of the sacrificial layers 114 and 120 from under the portions of the channel layers 118 and 122 that are in the channel region 106 .
- the now suspended portions of the channel layers 118 and 122 in the channel region 106 function as nanowire channels 128 and 130 (best seen in FIG. 8B .
- the ESEW layer 110 has functioned as an etch stop during the etching process to prevent etching of trenches in the substrate 108 or ESEW layer 110 . Therefore, the ESEW layer 110 of the GAA MOSFET structure 100 is free of any trenches under the nanowire channels 128 and 130 . This now very uniform structure helps to prevent performance irregularities between devices in the GAA MOSFET structure 100 .
- FIG. 8B a cross sectional view of GAA MOSFET structure 100 taken along sectional line 8 B- 8 B is presented.
- the cross section is through the nanowire channels 128 and 130 of one of the fins 124 .
- the source 102 and drain 104 regions have the same structure. They source and drain regions 102 , 104 include the substrate 108 having the protective ESEW layer 110 disposed over it. The sacrificial layer 114 is still intact and is disposed over the ESEW layer 110 . The channel layer 118 is disposed over the sacrificial layer 114 . The second sacrificial layer 120 is disposed over the channel layer 118 and the second channel layer 122 is disposed over the second sacrificial layer 120 .
- the source and drain regions 102 and 104 are illustrated as being planar in shape, but may be patterned into other shapes, such as fin shaped, as well.
- the common boundary 112 is located in the source 102 , the drain 104 and the channel 106 regions, and provides an n-p or a p-n junction which forms an electric well opposing current leakage to the substrate 108 in all three regions.
- the sacrificial layers, especially the n-type doped sacrificial layer 114 provide an added electrical well at the common boundary 116 in the source 102 and drain 104 regions. Therefore the sacrificial layers 114 and 120 are not usually removed from the source and drain regions 102 and 104 .
- the now suspended nanowire channels 130 and 128 extend horizontally relative to the substrate 108 across the entire channel region.
- the channels 130 and 128 are anchored to the channel layers 122 and 118 in the source 102 and drain 104 regions of structure 100 .
- FIG. 9 a cross sectional view of the channel region 106 of the completed GAA MOSFET structure 100 in accordance with the present invention is presented.
- a gate high-k dielectric 132 is disposed entirely around the nanowire channels 128 and 130 , over the STI layers 126 , and over the ESEW layer 110 .
- a gate metal is next disposed around the entirety of the dielectric 132 covered channels 128 and 130 and over the dielectric 132 covered STI layer 126 and ESEW layer 110 to form the gate electrode 134 and complete the GAA MOSFET structure 100 .
- the ESEW layer 110 has functioned as an etch stop during the etching process to prevent etching of trenches in the substrate 108 or ESEW layer 110 . Therefore, the ESEW layer 110 of the GAA MOSFET structure 100 is free of any trenches under the nanowire channels 128 and 130 .
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Abstract
Description
- The present invention relates to semiconductor devices and methods of fabricating the same. More specifically, the invention relates to various methods of forming nanowire channels in gate-all-around (GAA) MOSFETs.
- With constant down-scaling and increasingly demanding requirements to the speed and functionality of ultra-high density integrated circuits, conventional planar metal-oxide-semiconductor field effect transistors (MOSFETs) face increasing challenges with such issues as scaling of gate oxide thickness and electrostatic control of the gate electrode over the channel region. Fin field effect transistors (FinFETs) have exhibited improved control over a planar gate MOSFET design by wrapping the gate electrode over three sides of a fin-shaped channel.
- GAA MOSFETs are similar to FinFETs but have the potential of even greater electrostatic control over the channel because the gate electrode completely surrounds the channel. In a GAA MOSFET, the channel region is essentially a nanowire. The nanowire channel typically has a thickness (or diameter) in the tens of nanometers (nm) or less and has an unconstrained length. The nanowire channel is suspended generally horizontally between, and anchored to, the much larger source and drain regions of the GAA MOSFET.
- GAA MOSFETs can be fabricated on a bulk silicon substrate utilizing fully compatible CMOS technology. A typical manufacturing method of forming the channel regions in a GAA MOSFET involves epitaxially growing a stack (epi-stack) of sacrificial layers sandwiched between channel layers on top of a bulk substrate. The sacrificial layers and channel layers are composed of two different materials so that selective etching can remove the sacrificial layers.
- By way of example, an epi-stack can be formed of alternating silicon (Si) and silicon germanium (SiGe) layers, wherein the Si layers are the sacrificial layers and the SiGe layers are the channel layers. The Si layers can then be removed by selective etching (for example via a wet etching process such as a TMAH), which also inadvertently recesses trenches into the bulk substrate due to the similarity of materials composing the sacrificial layers and the substrate. The SiGe layers can subsequently be formed into the nanowire channels suspended over the trenches. A thin gate dielectric is then disposed around the SiGe nanowire channels and over the recessed trenches of the substrate. Metal is then disposed over the dielectric to form the metal gate electrode of the GAA MOSFET.
- Problematically however, it is difficult to control the inadvertent etching of the recessed trenches under the nanowire channels. This uncontrolled etch introduces trench to trench variations and an undesired roughness at the bottoms of the trenches, which can detrimentally affect device performance. Additionally, the thin gate dielectric deposition does not always sufficiently isolate the metal gate from the substrate, which can lead to shorts across the gate dielectric from electrode to substrate.
- Accordingly, there is a need for a method of forming nanowire channels in GAA MOSFETs, which provides better control of the etching process during removal of sacrificial layers with little or no trench formation. Moreover, there is a need for a method of forming nanowire channels, which prevents electrical shorts across the gate dielectric.
- The present invention offers advantages and alternatives over the prior art by providing a GAA MOSFET and methods of making the same, wherein the MOSFET includes an etch stop-electric well (ESEW) layer disposed over a substrate. The ESEW layer functions as an etch stop barrier to prevent etching of trenches in the substrate during an etching removal process of any sacrificial layers when making the MOSFET. The ESEW layer additionally provides an electric barrier against potential shorts across the gate dielectric by providing an additional p-n or n-p barrier at the common boundary between ESEW layer and substrate.
- A method of making a GAA MOSFET in accordance with one or more aspects of the present invention includes providing a substrate having source, drain and channel regions for a GAA MOSFET, the substrate being doped with one of a p-type and an n-type dopant. An etch stop-electric well (ESEW) layer is then disposed over the substrate, the ESEW layer is doped with the other of the p-type and the n-type dopant. A sacrificial layer is disposed over the ESEW layer, the sacrificial layer is doped with the same type dopant as the substrate. A channel layer is disposed over the sacrificial layer. The method further includes patterning a fin out of the ESEW layer, sacrificial layer, and channel layer in the channel region. Additionally the method includes selectively etching away only the sacrificial layer of the fin to form a nanowire from the channel layer of the fin while the ESEW layer of the fin functions as an etch stop barrier to prevent etching of trenches in the substrate.
- In another exemplary embodiment of the invention, a GAA MOSFET includes a substrate doped with one of an n-type and a p-type dopant. An etch stop-electric well (ESEW) layer is disposed over the substrate. The ESEW layer is doped with the other of the n-type and p-type dopant and is composed of a different material than the substrate. The GAA MOSFET also includes a source, drain and channel region disposed over the ESEW layer, the channel region having a nanowire channel connected between the source and drain regions. A gate dielectric coating is disposed over the nanowire channel and the ESEW layer in the channel region. A gate metal is disposed over the gate dielectric coating in the channel region to form a gate electrode of the GAA MOSFET. The ESEW layer is free of any trenches under the nanowire channel.
- The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
-
FIG. 1 is perspective view of an exemplary prior art GAA MOSFET structure; -
FIG. 2A is a perspective view of the prior art GAA MOSFET structure ofFIG. 1 at an intermediate stage of manufacturing; -
FIG. 2B is a cross sectional view of prior artFIG. 2A taken along thesectional line 2B-2B; -
FIG. 3 is the cross sectional view of prior artFIG. 2B further patterned in the channel region to form a pair of fins; -
FIG. 4 is the cross sectional view of prior artFIG. 3 after selective removal of sacrificial layers; -
FIG. 5 is the cross sectional view of the channel region of the completed prior art GAA MOSFET structure; -
FIG. 6 is a cross sectional view of a GAA MOSFET structure at an intermediate stage of manufacturing in accordance with the present invention; -
FIG. 7 is a cross sectional view ofFIG. 6 further patterned in the channel region to form a pair of fins in accordance with the present invention; -
FIG. 8A is a cross sectional view ofFIG. 7 after selective removal of sacrificial layers in accordance with the present invention; -
FIG. 8B is a cross sectional view ofGAA MOSFET structure 100 taken alongsectional line 8B-8B ofFIG. 8A ; and -
FIG. 9 is a cross sectional view of the channel region of the completed GAA MOSFET structure in accordance with the present invention. - Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the methods, systems, and devices disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the methods, systems, and devices specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention.
-
FIGS. 1-5 illustrate various exemplary embodiments of a prior art GAA MOSFET and methods of making the same. - Referring to
FIG. 1 , a simplistic perspective view of an exemplary prior artGAA MOSFET structure 10 is presented.GAA MOSFET 10 includes asource region 12, adrain region 14 and achannel region 16 embedded in asubstrate 18. - The
source 12 and drain 14 regions are shown as planar in shape, but can be other shapes as well, such as in the form of a fin to make theMOSFET 10 essentially a FinFET. In this exemplary embodiment, thechannel region 16 includes a pair ofnanowire channels 20 extending horizontally relative to a topplanar surface 22 of thesubstrate 18. For simplicity purposes, the gate dielectric and all-around gate electrode, which surround thenanowire channels 20, are not shown. The gate electrode is operable to control electric conduction through thenanowire channels 20 fromsource 12 to drain 14 as is well known. - Though this embodiment illustrates a pair of
nanowire channels 20, any number of such channels may be included in thechannel region 16. Moreover, the nanowire channels may be oriented in a row (as is shown) extending horizontally across theplanar surface 22 of thesubstrate 18, or stacked vertically in columns extending vertically normal to theplanar surface 22. - During manufacture, the
source 12, drain 14 andnanowire channels 16 are typically patterned from an alternating plurality of epitaxially grownsacrificial layers 24 andchannel layers 26 disposed over thesurface 22 of thesubstrate 18. During the manufacturing process, thesacrificial layer 24 is removed, generally by a wet etch process such as with a tetra-methyl ammonium hydroxide (TMAH) solution, in thechannel region 16. The remainingchannel layer 26 is then further patterned to form thenanowire channels 20. Again, for purposes of simplicity, this embodiment only shows onesacrificial layer 24 and onechannel layer 26, but any number of such pairs may be utilized to form a stacked column of any number ofnanowire channels 20. - Referring to
FIG. 2A , a simplified perspective view of the prior artGAA MOSFET structure 10 ofFIG. 1 at an intermediate stage of manufacturing is presented. Referring also toFIG. 2B , a cross sectional view ofFIG. 2A taken along thesectional line 2B-2B is also presented. - In
FIGS. 2A and 2B , thesacrificial layer 24 andchannel layer 26 have been epitaxially grown oversubstrate 18 to form an epi-stack. The twolayers substrate 18 is silicon (Si), thesacrificial layer 24 is also Si and thechannel layer 26 is silicon germanium (SiGe). - At this stage of manufacture, the
source region 12, thedrain region 14 and thechannel region 16 include only unpatterned portions of the epitaxially grown Sisacrificial layer 24 disposed over theSi substrate 18, and the epitaxially grownSiGe channel layer 26 disposed over the sacrificial layer. The cross sectional view inFIG. 2B is taken through thechannel region 16. - Referring to
FIG. 3 , theGAA MOSFET structure 10 has been further patterned in thechannel region 16 to form a pair offins 28 out of theSiGe channel layer 26, the Sisacrificial layer 24 and a portion ofsubstrate 18. One or more dielectric materials (such as silicon dioxide) are deposited in trenches and polished down to thetop surface 22 of thesubstrate 18 to form a plurality of shallow trench isolation (STI) layers 30. The STI layers 30 extend along the length of thefins 28 to prevent current leakage between the nanowire channels that are to be formed in the fins. - Referring to
FIG. 4 , a wet etching process (such as TMAH etching) is utilized to selectively remove the remainder of thesacrificial layer 24 from under the portion ofchannel layer 26 that is in thechannel region 16. The now suspended portions of thechannel layer 26 in thechannel region 16 function as the nanowire channels 20 (best seenFIG. 1 ). - Problematically however, because the
substrate 18 material andsacrificial layer 24 material are generally very similar (in this exemplary case they are both exactly the same silicon material), the etching process inadvertently recessestrenches 32 into thesubstrate 18. This uncontrolled etching process forms rough irregular bottoms to thetrenches 32, which varies from trench to trench and can detrimentally affect device performance. - Referring to
FIG. 5 , agate dielectric 34 is disposed entirely around thenanowire channels 20, over the STI layers 30, and overtrenches 30 recessed insubstrate 18. The gate dielectric is preferably a high-k dielectric (with a high dielectric constant as compared to silicon dioxide). Examples of high-k dielectrics are hafnium silicate, zirconium silicate, hafnium dioxide, zirconium dioxide and the like. The high-k dielectric material is typically deposited using an atomic layer deposition process. - A gate metal is next disposed around the entirety of the dielectric 34 covered
channels 20 and over the dielectric 34 coveredSTI layer 30 andsubstrate 18 to form thegate electrode 36 and complete theGAA MOSFET structure 10. The gate metal may be such metals as Tantalum (Ta), Tantalum Nitride (TaN), Niobium (Nb), Tungsten Nitride, Ruthenium Oxide and the like. - Problematically however, the deposition process in the area of the
trenches 32 under thechannels 20 is difficult to complete andirregular voids 38 are often formed. Moreover, the gate dielectric is very thin and sometimes does not adequately isolate thegate electrode 36 from thesubstrate 18. This is especially problematic at the rough bottoms of thetrenches 32, where uniform deposition of thedielectric coating 34 is difficult to control. As a result, the potential for electrical shorts to occur across the dielectric 34 fromgate 36 tosubstrate 18 is higher within the irregular shapedtrenches 32. -
FIGS. 6-9 illustrate various exemplary embodiments of a GAA MOSFET and methods of making the same in accordance with the present invention. - Referring to
FIG. 6 , a cross sectional view of aGAA MOSFET structure 100 at an intermediate stage of manufacturing in accordance with the present invention is presented.FIG. 6 is analogous to prior artFIG. 2B in that both illustrate cross sections through channel regions of their respective GAA MOSFETs after epitaxially grown layers have been disposed on the surface of a substrate and prior to fin formation. - In the specific case of
FIG. 6 , theGAA MOSFET structure 100 has a source region 102 (best seen inFIG. 8B ) and a drain region 104 (best seen inFIG. 8B ) interconnected by achannel region 106. Thechannel region 106 includes asilicon substrate 108, which, for this particular exemplary embodiment, is doped with an n-type dopant, such as phosphorus, arsenic or the like, to provide an n-type semiconductor material. - Even though this example illustrates an n-type Si substrate, the
substrate 108 could also have been doped with a p-type dopant, such as boron, gallium or the like. Thesubstrate 108 could also have been of a material other than Si, such as germanium (Ge), silicon germanium (SiGe) or the like. - Advantageously, an etch stop-electric well (ESEW)
layer 110 is disposed over the surface of thesubstrate 108.ESEW layer 110 is doped with a p-type dopant since thesubstrate 108 is doped n-type. That is, if thesubstrate 108 is be doped with one of an n-type and a p-type dopant, then theESEW layer 110 will be doped with the other of the n-type and p-type dopant. In this way, an n-p junction or a p-n junction is formed at thecommon boundary 112 between thesubstrate 108 and theESEW layer 110. The n-p junction (or n-p junction) induces a depletion region which functions as an electric voltage barrier (or electric well) to any leakage current fromESEW layer 110 tosubstrate 108. - The
ESEW layer 110 is also composed of a different material than thesubstrate 108. In this exemplary embodiment, thesubstrate 108 is Si and the ESEW layer is composed of SiGe. This is done so that theESEW layer 110 not only functions as an electric well opposing current leakage to thesubstrate 108, but also advantageously functions as an etch stop that protects the substrate during any selective etching process ofstructure 100. - Though in this embodiment SiGe was selected as the material composition for the
ESEW layer 110, one skilled in the art would recognize that many other materials can be used. However, the material for theESEW layer 110 should be different enough from the material of thesubstrate 108 such that the ESEW layer will not readily etch, or preferably not etch at all, during an etching process that would readily etch the substrate. - A
sacrificial layer 114 is disposed over the top surface of theESEW layer 110.Sacrificial layer 114 is typically composed of a very similar material to that of thesubstrate 108, and, therefore, is composed of a very different material to that of theESEW layer 110. In this embodiment, thesacrificial layer 114 is composed of Si, the exact same material as thesubstrate 108. As a result, thesacrificial layer 108 can be removed through selective etching, such as wet etching, while theESEW layer 110 functions as an etch stop during the etching process. - Advantageously, the
sacrificial layer 114 is also doped with the same type dopant as thesubstrate 108. In this exemplary embodiment, both thesacrificial layer 114 andsubstrate 108 are doped with an n-type dopant. As a result, an additional n-p junction is set up at thecommon boundary 116 betweensacrificial layer 114 and theESEW layer 110. Accordingly, and additional electric well (or electric voltage barrier) is formed which further opposes any leakage current to thesubstrate 108. Indeed, thecommon boundaries sacrificial layer 114, theESEW layer 110 and thesubstrate 108 collectively form an n-p-n junction, which strongly resists leakage current or potential shorts to thesubstrate 108. - One skilled in the art would recognize that if the
substrate 108 were doped with a p-type dopant, then theESEW layer 114 would necessarily be doped with an n-type dopant and the sacrificial layer would also necessarily be doped with a p-type dopant. As a result, a p-n junction would be induced atboundary 116, and a p-n-p junction would be induced collectively acrossboundaries - A
channel layer 118, similar in material composition to theESEW layer 110, is disposed over thesacrificial layer 114. In this embodiment,channel layer 118 is composed of SiGe, which is the same material as theESEW layer 110. Disposed over thechannel layer 118 is a secondsacrificial layer 120 composed of Si, and disposed over the secondsacrificial layer 120 is asecond channel layer 122 composed of SiGe. - Though this embodiment shows two epitaxially grown
sacrificial layers - Referring to
FIG. 7 , in a similar process to that illustrated in prior artFIG. 3 , theGAA MOSFET 100 has been further patterned in thechannel region 106 to form a pair of fins 124 out of the channel layers 122 and 118, thesacrificial layer ESEW layer 110 and a portion of thesubstrate 108. Additionally a plurality of STI layers 126 have been disposed between the fins 124 to prevent current leakage there between. Though two fins 124 have been patterned in this embodiment, one skilled in the art would recognize that any plurality of fins may be patterned in thechannel region 106. - Referring to
FIG. 8 , in a similar process to that illustrated in prior artFIG. 4 , a wet etch process is utilized to selectively remove the remainder of thesacrificial layers channel region 106. The now suspended portions of the channel layers 118 and 122 in thechannel region 106 function asnanowire channels 128 and 130 (best seen inFIG. 8B . - Advantageously however, and very much unlike the process illustrated in prior art
FIG. 4 , theESEW layer 110 has functioned as an etch stop during the etching process to prevent etching of trenches in thesubstrate 108 orESEW layer 110. Therefore, theESEW layer 110 of theGAA MOSFET structure 100 is free of any trenches under thenanowire channels GAA MOSFET structure 100. - Referring to
FIG. 8B , a cross sectional view ofGAA MOSFET structure 100 taken alongsectional line 8B-8B is presented. The cross section is through thenanowire channels - In this exemplary embodiment, the
source 102 and drain 104 regions have the same structure. They source and drainregions substrate 108 having theprotective ESEW layer 110 disposed over it. Thesacrificial layer 114 is still intact and is disposed over theESEW layer 110. Thechannel layer 118 is disposed over thesacrificial layer 114. The secondsacrificial layer 120 is disposed over thechannel layer 118 and thesecond channel layer 122 is disposed over the secondsacrificial layer 120. The source and drainregions - The
common boundary 112 is located in thesource 102, thedrain 104 and thechannel 106 regions, and provides an n-p or a p-n junction which forms an electric well opposing current leakage to thesubstrate 108 in all three regions. The sacrificial layers, especially the n-type dopedsacrificial layer 114, provide an added electrical well at thecommon boundary 116 in thesource 102 and drain 104 regions. Therefore thesacrificial layers regions - However, under some applications it is possible that it may be advantageous to remove all or a portion of the
sacrificial layers source 102 and drain 104 regions. For example, to promote greater surface contact between metal and the source and drain semiconductor materials. - In the
channel region 106, the now suspendednanowire channels substrate 108 across the entire channel region. Thechannels source 102 and drain 104 regions ofstructure 100. - Referring to
FIG. 9 , a cross sectional view of thechannel region 106 of the completedGAA MOSFET structure 100 in accordance with the present invention is presented. In a similar process to that illustrated in prior artFIG. 5 , a gate high-k dielectric 132 is disposed entirely around thenanowire channels ESEW layer 110. A gate metal is next disposed around the entirety of the dielectric 132 coveredchannels STI layer 126 andESEW layer 110 to form thegate electrode 134 and complete theGAA MOSFET structure 100. - Advantageously however, and very much unlike the process illustrated in prior art
FIG. 5 , theESEW layer 110 has functioned as an etch stop during the etching process to prevent etching of trenches in thesubstrate 108 orESEW layer 110. Therefore, theESEW layer 110 of theGAA MOSFET structure 100 is free of any trenches under thenanowire channels - Although the invention has been described by reference to specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims.
Claims (20)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US14/970,661 US9704962B1 (en) | 2015-12-16 | 2015-12-16 | Horizontal gate all around nanowire transistor bottom isolation |
TW105122021A TWI624871B (en) | 2015-12-16 | 2016-07-13 | Horizontal gate all around nanowire transistor bottom isolation |
CN201611166370.8A CN107039503B (en) | 2015-12-16 | 2016-12-16 | Bottom isolation of horizontal gate surrounding nanowire transistors |
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Also Published As
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TWI624871B (en) | 2018-05-21 |
CN107039503A (en) | 2017-08-11 |
TW201735160A (en) | 2017-10-01 |
CN107039503B (en) | 2020-09-22 |
US9704962B1 (en) | 2017-07-11 |
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