U.S. patent application number 15/491465 was filed with the patent office on 2017-08-03 for semiconductor structure(s) with extended source/drain channel interfaces and methods of fabrication.
This patent application is currently assigned to GLOBALFOUNDRIES Inc.. The applicant listed for this patent is GLOBALFOUNDRIES Inc.. Invention is credited to Edmund Kenneth BANGHART, Shesh Mani PANDEY, Mitsuhiro TOGO.
Application Number | 20170222054 15/491465 |
Document ID | / |
Family ID | 55268035 |
Filed Date | 2017-08-03 |
United States Patent
Application |
20170222054 |
Kind Code |
A1 |
BANGHART; Edmund Kenneth ;
et al. |
August 3, 2017 |
SEMICONDUCTOR STRUCTURE(S) WITH EXTENDED SOURCE/DRAIN CHANNEL
INTERFACES AND METHODS OF FABRICATION
Abstract
Semiconductor structures and methods of fabrication are
provided, with one or both of an extended source-to-channel
interface or an extended drain-to-channel interface. The
fabrication method includes, for instance, recessing a
semiconductor material to form a cavity adjacent to a channel
region of a semiconductor structure being fabricated, the recessing
forming a first cavity surface and a second cavity surface within
the cavity; and implanting one or more dopants into the
semiconductor material through the first cavity surface to define
an implanted region within the semiconductor material, and form an
extended channel interface, the extended channel interface
including, in part, an interface of the implanted region within the
semiconductor material to the channel region of the semiconductor
structure. In one embodiment, the semiconductor structure with the
extended channel interface is a FinFET.
Inventors: |
BANGHART; Edmund Kenneth;
(Pittsford, NY) ; TOGO; Mitsuhiro; (Ballston Lake,
NY) ; PANDEY; Shesh Mani; (Clifton Park, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GLOBALFOUNDRIES Inc. |
Grand Cayman |
|
KY |
|
|
Assignee: |
GLOBALFOUNDRIES Inc.
Grand Cayman
KY
|
Family ID: |
55268035 |
Appl. No.: |
15/491465 |
Filed: |
April 19, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14454778 |
Aug 8, 2014 |
9679990 |
|
|
15491465 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 21/26513 20130101;
H01L 29/7851 20130101; H01L 29/0847 20130101; H01L 29/785 20130101;
H01L 29/66636 20130101; H01L 29/1033 20130101; H01L 29/66795
20130101 |
International
Class: |
H01L 29/78 20060101
H01L029/78; H01L 21/265 20060101 H01L021/265; H01L 29/10 20060101
H01L029/10; H01L 29/66 20060101 H01L029/66; H01L 29/08 20060101
H01L029/08 |
Claims
1. A device comprising: a semiconductor structure, the
semiconductor structure comprising: a source region and a drain
region separated by a channel region, the channel region residing
within a semiconductor material; the source region comprising an
implanted source region within the semiconductor material and an
epitaxial source region being disposed above the implanted source
region; and the drain region comprising an implanted drain region
within the semiconductor material and an epitaxial drain region
being disposed above the implanted drain region; wherein the
implanted source region provides the semiconductor structure with
an extended source channel interface, the epitaxial source region
provides the semiconductor structure with an extended source
channel interface comprising, in part, a sidewall interface of the
epitaxial source region to the channel region, the implanted drain
region provides the semiconductor structure with an extended drain
channel interface, and the epitaxial drain region provides the
semiconductor structure with an extended drain channel interface
comprising, in part, a sidewall interface of the epitaxial drain
region to the channel region.
2. The device of claim 1, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
3. The device of claim 2, wherein the extended source channel
interface and the extended drain channel interface increase
junction on-current while minimizing junction leakage current of
the FinFET.
4. The device of claim 1, wherein an interface of the implanted
source region to the channel region is at an angle relative to the
sidewall interface of the epitaxial source region to the channel
region, and wherein an interface of the implanted drain region to
the channel region is at an angle relative to the sidewall
interface of the epitaxial drain region to the channel region.
5. The device of claim 4, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
6. The device of claim 5, wherein the extended source channel
interface and the extended drain channel interface increase
junction on-current while minimizing junction leakage current of
the FinFET.
7. The device of claim 1, wherein an interface of the implanted
source region to the channel region is non-planar with the sidewall
interface of the epitaxial source region to the channel region, and
wherein an interface of the implanted drain region to the channel
region is non-planar with the sidewall interface of the epitaxial
drain region to the channel region.
8. The device of claim 7, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
9. The device of claim 8, wherein the extended source channel
interface and the extended drain channel interface increase
junction on-current while minimizing junction leakage current of
the FinFET.
10. The device of claim 1, wherein an interface of the implanted
source region to the channel region is coplanar with the sidewall
interface of the epitaxial source region to the channel region, and
wherein an interface of the implanted drain region to the channel
region is coplanar with the sidewall interface of the epitaxial
drain region to the channel region.
11. The device of claim 10, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
12. The device of claim 11, wherein the extended source channel
interface and the extended drain channel interface increase
junction on-current while minimizing junction leakage current of
the FinFET.
13. A device comprising: a semiconductor structure, the
semiconductor structure comprising: a source region and a drain
region separated by a channel region, the channel region residing
within a semiconductor material and the source region and the drain
region respectively comprising an implanted source region within
the semiconductor material and an implanted drain region within the
semiconductor material ; and wherein the implanted source region
provides the semiconductor structure with an extended source
channel interface and the implanted drain region provides the
semiconductor structure with an extended drain channel
interface.
14. The device of claim 13, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
15. The device of claim 13, wherein an interface of the implanted
source region to the channel region is at an angle relative to the
sidewall interface of the epitaxial source region to the channel
region, and wherein an interface of the implanted drain region to
the channel region is at an angle relative to the sidewall
interface of the epitaxial drain region to the channel region.
16. The device of claim 15, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
17. The device of claim 13, wherein an interface of the implanted
source region to the channel region is non-planar with the sidewall
interface of the epitaxial source region to the channel region, and
wherein an interface of the implanted drain region to the channel
region is non-planar with the sidewall interface of the epitaxial
drain region to the channel region.
18. The device of claim 17, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
19. The device of claim 13, wherein an interface of the implanted
source region to the channel region is coplanar with the sidewall
interface of the epitaxial source region to the channel region, and
wherein an interface of the implanted drain region to the channel
region is coplanar with the sidewall interface of the epitaxial
drain region to the channel region.
20. The device of claim 19, wherein the semiconductor device
comprises a fin-type field effect transistor (FinFET) and the
extended source channel interface and the extended drain channel
interface together extend the channel region of the FinFET within
the semiconductor material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Non-Provisional
patent application Ser. No. 14/454,778, which was filed on Aug. 8,
2014, which is hereby incorporated herein by reference in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to semiconductor structures,
and to methods of fabricating semiconductor structures, and in
particular to semiconductor structures with extended
source-to-channel interfaces and/or extended drain-to-channel
interfaces, and to methods of fabrication thereof.
BACKGROUND OF THE INVENTION
[0003] Semiconductor structures, such as field-effect transistors
(FETs), have conventionally been fabricated as planar circuit
elements. More recently, fin-type field-effect transistor (FinFET)
devices have been developed to replace planar transistors, such as
metal oxide semiconductor field-effect transistors (MOSFETs), in
advanced complementary metal oxide semiconductor (CMOS) technology,
due to their improved short channel effect immunity and higher
on-current to off-current ratio (I.sub.on/I.sub.off). As is known,
the term "fin" refers to a vertical structure within or upon which
are formed, for instance, one or more FinFETs or other fin devices,
such as passive devices, including capacitors, diodes, etc.
[0004] As described by Moore's Law, the semiconductor industry
continues to drive down pattern dimensions in order to reduce
transistor size and enhance processor speed at a rapid pace.
Further enhancements in transistor designs and fabrication methods
therefor continue to be pursued, for enhanced performance and
commercial advantage.
BRIEF SUMMARY
[0005] The shortcomings of the prior art are overcome, and
additional advantages are provided, through the provision, in one
aspect, of a method, which includes: recessing a semiconductor
material to form a cavity therein adjacent to a channel region of a
semiconductor structure being fabricated, the recessing forming a
first cavity surface and a second cavity surface within the cavity;
and implanting one or more dopants into the semiconductor material
through the first cavity surface to define an implanted region
within the semiconductor material, and form an extended channel
interface, the extended channel interface including, in part, an
interface of the implanted region within the semiconductor material
to the channel region of the semiconductor structure.
[0006] In a further aspect, a device is provided which includes a
semiconductor structure. The semiconductor structure includes a
source region and a drain region separated by a channel region, the
channel region residing within a semiconductor material and the
source region and the drain region respectively including an
implanted source region within a semiconductor material and an
implanted drain region within the semiconductor material. Further,
the implanted source region provides the semiconductor structure
with an extended source channel interface and the implanted drain
region provides the semiconductor structure with an extended drain
channel interface.
[0007] Additional features and advantages are realized through the
techniques of the present invention. Other embodiments and aspects
of the invention are described in detail herein and are considered
a part of the claimed invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] One or more aspects of the present invention are
particularly pointed out and distinctly claimed as examples in the
claims at the conclusion of the specification. The foregoing and
other objects, features, and advantages of the invention are
apparent from the following detailed description taken in
conjunction with the accompanying drawings in which:
[0009] FIGS. 1A-1C depict one embodiment of a process for
fabricating a semiconductor structure with a source channel
interface and a drain channel interface which may be modified, in
accordance with one or more aspects of the present invention;
[0010] FIG. 2A is a partial cross-sectional elevational view of one
embodiment of a semiconductor structure obtained during device
fabrication, in accordance with one or more aspects of the present
invention;
[0011] FIG. 2B depicts the structure of FIG. 2A, after implanting
one or more dopants through a horizontal cavity surface of the
source and drain cavities to define implanted source and drain
regions, respectively, in accordance with one or more aspects of
the present invention;
[0012] FIG. 2C depicts the structure of FIG. 2B, after provision of
epitaxial source and drain regions at least partially within the
source and drain cavities, respectively, completing one embodiment
of the extended source and drain channel interfaces, in accordance
with one or more aspects of the present invention;
[0013] FIG. 3A depicts an alternate embodiment of the structure of
FIG. 2C, with the implanted source and drain region interfaces to
the channel region extending at an angle relative to a sidewall
interface of the epitaxial source and drain regions to the channel
region, in accordance with one or more aspects of the present
invention;
[0014] FIG. 3B depicts another alternate embodiment of the
structure of FIG. 2C, with the implanted source and drain region
interfaces to the channel regions being parallel with the sidewall
interfaces of the epitaxial source and drain regions to the channel
region, in accordance with one or more aspects of the present
invention; and
[0015] FIG. 3C depicts an alternate embodiment of the structure of
FIG. 2C, with the implanted source and drain region interfaces to
the channel regions being non-planar to the sidewall interfaces of
the epitaxial source and drain regions to the channel region, in
accordance with one or more aspects of the present invention.
DETAILED DESCRIPTION
[0016] Aspects of the present invention and certain features,
advantages, and details thereof, are explained more fully below
with reference to the non-limiting embodiments illustrated in the
accompanying drawings. Descriptions of well-known materials,
fabrication tools, processing techniques, etc., are omitted so as
to not unnecessarily obscure the invention in detail. It should be
understood, however, that the detailed description and the specific
examples, while indicating embodiments of the invention, are given
by way of illustration only, and are not by way of limitation.
Various substitutions, modifications, additions and/or arrangements
within the spirit and/or scope of the underlying inventive concepts
will be apparent to those skilled in the art from this disclosure.
Also note that reference is made below to the drawings, which are
not drawn to scale for ease of understanding, wherein the same
reference numbers used throughout different figures designate the
same or similar components.
[0017] Disclosed herein, in part, is a method of fabricating a
semiconductor structure with an extended source-to-channel
interface and an extended drain-to-channel interface within a
semiconductor material, which advantageously improves circuit
performance by extending the positioning of the source and drain
regions into the semiconductor material adjacent to the channel
region of the semiconductor structure. During fabrication of
semiconductor devices such as, for instance, fin-type field-effect
transistor (FinFET) devices, a gate structure is typically wrapped
around the channel region of one or more fin structures or fin(s).
In operation of such FinFET devices, when an appropriate voltage is
applied on the gate structure, charge carriers (for instance,
electrons (generated by n-type dopants) or holes (generated by
p-type dopants)) will flow from a source region to a drain region
through a channel region of the device below the gate. However,
with continual decreased scaling of transistors, a challenge exists
for reducing device-on resistance, without increasing short channel
effect (SCE) or punch-through current leakage. Increasing effective
depth of the channel region by exposing a greater surface area of
the fin(s) and wrapping the gate structures around the exposed
portion of the fin(s), for instance, facilitates increasing current
charge inversion within the fin(s) which, in one example, may be
one solution to the problem. Note that such an increase in the
effective depth of the channel region disadvantageously creates a
mis-match though between the positioning of the source and drain
regions and the exposed channel region underlying the gate
structure, potentially resulting in increasing device-on resistance
of the resultant FinFET device(s).
[0018] By way of example, FIGS. 1A-1C illustrate one embodiment of
a process for fabricating a semiconductor device, such as a
fin-type field-effect transistor (FET), which includes, for
instance, a source-to-channel interface and a drain-to-channel
interface. Referring to FIG. 1A, a cross-sectional elevational view
is shown of a structure 100 obtained during one embodiment of a
method for fabricating a semiconductor structure, such as planar
field-effect transistor, or fin-type field-effect transistor. In
the illustrated example, a substrate 101, which may be a
semiconductor substrate, is provided, along with a gate structure
110 overlying a channel region 102 within substrate 101. By way of
example, gate structure 110 may be a sacrificial gate structure for
use in a gate-last process, in which gate structures are provided
after establishment of the source region and the drain region of
the semiconductor structure. In one embodiment, gate structure 110
includes, by way of example only, a sacrificial gate material 112
(such as polysilicon), and sidewall spacers 114 (formed, for
example, from an oxide material). If desired, a gate cap (not
shown) may be provided over sacrificial gate material 112. Note
that in another embodiment, gate structure 110 could be a gate
structure of a typical gate-first process, in which gate structures
are provided before establishment of the source and drain regions
of the transistor. In such a case, the sacrificial gate material
would be replaced by one or more gate metals disposed above a gate
dielectric, both of which may be surrounded or protected by
sidewall spacers 114. An isolation region 120, such as shallow
trench isolation, may at least partially surround the semiconductor
structure.
[0019] By way of example, substrate 101 may be a bulk semiconductor
material, such as a bulk silicon wafer. In another example, the
substrate may be or include any silicon-containing substrate
material including, but not limited to, single-crystal Si,
polycrystalline Si, amorphous Si, Si-on-nothing (SON),
Si-on-insulator (SOI), or Si-on-replacement insulator (SRI)
substrates, and the like, and may be N-type or P-type doped, as
desired for a particular application. In a further example, the
substrate may be, for instance, a wafer or substrate approximately
600-700 micrometers thick, or less. The substrate may include other
suitable elementary semiconductors, such as, for example, germanium
(Ge), a crystal, or a compound semiconductor such as silicon
carbide (SiC), gallium arsenide (GaAs), gallium phosphide (GaP),
indium phosphide (InP), indium arsenide (InAs), and/or indium
antimonide (InSb), or combinations thereof; or an alloy
semiconductor including: GaAsP, AlInAs, GaInAs, GaInP, or GaInAsP,
or combinations thereof. In another example, substrate 101 may
include multiple layers of material.
[0020] In another embodiment, substrate 101 may include one or more
three-dimensional fin structures, which extend from the substrate.
In such a case, the gate structures may wrap up, over, and down the
fin structure, so that a control voltage may be applied at two or
more surfaces of the fin structure, and in particular, to two or
more surfaces of a channel region of the fin structure, allowing
for a greater current to flow through the structure between a
source region and a drain region during operation.
[0021] As illustrated in FIG. 1B, substrate 101 is recessed
adjacent to channel region 102 to form one or more cavities 130
therein, including, for instance, a source cavity and a drain
cavity, separated by channel region 102. A variety of processing
techniques may be employed to pattern substrate 101, and remove
material thereof to form cavities 130, each with a first cavity
surface 132 and a second cavity surface 133. For example, substrate
101 may be patterned using direct lithography, sidewall image
transfer techniques, extreme ultra-violet lithography (EUV), e-beam
techniques, litho-etch techniques, or litho-etch-litho-freeze
techniques. Removal of material may be accomplished using any
suitable removal process, such as an etching process with an
etchant selected to etch, for instance, the material of the
substrate. In one specific example, reactive ion etching may be
performed using fluorine-based chemistry, and gases such as
tetrafluoromethane (CF4), trifluoromethane (CHF3), difluoromethane
(CH2F2), fluoromethane (CH3F), octofluoromethane (C4F8),
hexafluoro-1,3-butadiene (C4F6), sulfur hexafluoride (SF6), oxygen
(O2), and the like. In one implementation, cavities 130 may be box
shaped with nearly perpendicular side walls. In another
implementation, cavities 130 may have other shapes, and may have
angular sidewalls. In one specific implementation, cavities 130 may
be sigma cavities, which are named for the resemblance between the
Greek-letter E (sigma) and the profile of its angular sidewall
planes, which may include {111}, {110}, and/or {100} planes.
[0022] FIG. 1C illustrates the structure of FIG. 1B after forming
source and drain regions 134, at least partially, within source and
drain cavities 130 (FIG. 1B). In one embodiment, source and drain
regions 134 may be formed by, for instance, epitaxially growing a
source and drain material from the exposed semiconductor material
of substrate 101 within source and drain cavities 130 (FIG. 1B).
Epitaxial growing refers to the orderly growth of a crystalline
material, where the grown material arranges itself in the same
crystal orientation as the underlying structure. In one example,
the source and drain material may be epitaxially grown using
selective epitaxial growth via various methods such as, for
example, CVD, low-pressure CVD (LPCVD), or other applicable
methods. By way of example, in the case of a p-type, field-effect
transistor, the epitaxially grown source and drain regions 134 may
be doped silicon germanium-based epitaxy, and in the case of an
n-type, field-effect transistor, the source and drain regions 134
may be silicon-based epitaxy.
[0023] One challenge with the above-described approach for forming
source and drain regions adjacent to the channel region of the
semiconductor structure is that the depth of the source-to-channel
interface and depth of the drain-to-channel interface is limited,
for instance, by the depth of the recessed source and drain
cavities. For instance, as noted above, in the case of fin-type
field-effect-transistor, the effective depth of the channel region
may be increased by exposing a greater surface area of the fin(s)
and subsequently wrapping the gate structure around the exposed
portion of the fin(s). In such a case, the advantages of a greater
gate-to-channel surface area are not captured as the depth of the
recessed source and drain cavities cannot be easily extended to
match the depth of the source-to-channel interface and the
drain-to-channel interface. The newly exposed portion of the
channel region, which would normally result in increasing the
device on-current of the resultant FinFET device(s), is therefore
underutilized and, in particular, will contribute to undesirable
parasitic resistances and capacitances of the resultant FinFET
device(s).
[0024] FIGS. 2A-2C depict one embodiment of a transistor
fabrication process which extends the source-to-channel interface
and the drain-to-channel interface relative to the channel region
of the semiconductor device(s) without the above-noted
limitations.
[0025] Before discussing the exemplary process of FIGS. 2A-2C,
however, generally stated, provided herein are methods for
fabricating semiconductor structures with extended
source-to-channel interfaces and extended drain-to-channel
interfaces. The method includes, for instance, recessing a
semiconductor material to form a cavity therein adjacent to a
channel region of a semiconductor structure being fabricated, the
recessing forming a first cavity surface and a second cavity
surface within the cavity; and implanting one or more dopants into
the semiconductor material through the first cavity surface to
define an implanted region within the semiconductor material, and
form an extended channel interface, the extended channel interface
including, in part, an interface of the implanted region within the
semiconductor material to the channel region of the semiconductor
structure.
[0026] By way of example, implanting the one or more dopants into
the semiconductor material through the first cavity surface
positions, at least in part, the interface of the implanted region
parallel to the second cavity surface of the cavity. In one
example, the one or more dopants being implanted into the
semiconductor material may be or include an n-type dopant such as,
for example, phosphorus, antimony or arsenic. In another example,
the one or more dopants being implanted into the semiconductor
material may be or include a p-type dopants such as, for example,
boron, aluminum, gallium or indium. In one implementation,
implanting the one or more dopants may also include implanting the
one or more dopants through the first cavity surface at an implant
angle which results in extending the interface of the implanted
region within the semiconductor material at an angle from the
second cavity surface of the cavity. Note that in another
implementation, the extended channel interface further includes, in
part, the second cavity surface of the cavity.
[0027] In one implementation, the interface of the implanted region
to the channel region may be non-planar with the second cavity
surface of the cavity. Further, the implanting may include
implanting the one or more dopants through the first cavity surface
while minimizing lateral diffusion of the one or more dopants
within the semiconductor material, thereby controlling location of
the interface of the implanted region within the semiconductor
material to the channel region. In another example, the implanting
may include implanting the one or more dopants into the
semiconductor material through the first cavity surface at an
implant angle which is normal to the first cavity surface, with the
implant angle facilitating forming the interface of the implanted
region to the channel region coplanar with the second cavity
surface. The implanting may also include implanting the one or more
dopants into the semiconductor material through the first cavity
surface with an implant energy which attains a depth of the
interface of the implanted region to the channel region at a
desired depth within the semiconductor material.
[0028] In another implementation, the method may include forming a
source region or a drain region within, at least partially, the
cavity subsequent to the implanting of the one or more dopants
through the first cavity surface. By way of example, this forming
may include epitaxially growing the source region or the drain
region at least partially within the cavity, where the implanting
and the epitaxially growing together define the extended channel
interface to the channel region of the semiconductor structure.
Advantageously, the implanted region within the semiconductor
material facilitates increasing junction on-current while
minimizing junction leakage current of the resultant semiconductor
structure. For instance, by placing the peak of the implanted
region sufficiently below the first cavity interface, the
crystalline order of the substrate is minimally disrupted such that
high-quality, low-defect epitaxial growth of the source and drain
regions is maintained.
[0029] In yet another implementation, the cavity is a source
cavity, the implanted region is an implanted source region, the
extended channel interface is an extended source channel interface,
and the recessing further includes recessing the semiconductor
material to also form a drain cavity adjacent to the channel
region. The implanting further includes implanting through a first
drain cavity surface the one or more dopants to form a drain
implanted region, and the method further includes epitaxially
growing a source region over the implanted source region and a
drain region over the implanted drain region, the implanting and
the epitaxially growing together define the extended source channel
interface and an extended drain channel interface. The implanting
may further include performing an annealing process, subsequent to
the implanting of the one or more dopants into the semiconductor
material, the annealing process facilitating stabilizing the
implanted region within the semiconductor material. Additionally,
in one embodiment, the method may further include fabricating a
fin-type field-effect transistor (FinFET), the FinFET being the
semiconductor structure, with the fabricating including the
recessing of the one or more cavities and the implanting of the one
or more dopants within the cavities, for instance, to extend the
channel region of the FinFET.
[0030] In another aspect, a device is disclosed which includes a
semiconductor structure, with a source region and a drain region
separated by a channel region. The channel region resides within a
semiconductor material, and the source region and the drain region
includes an implanted source region within the semiconductor
material and an implanted drain region within the semiconductor
material. The implanted source region provides the semiconductor
structure with an extended source channel interface and the
implanted drain region provides the semiconductor structure with an
extended drain channel interface.
[0031] Referring to FIG. 2A, a structure 200 is illustrated similar
or identical to structure 100 of FIG. 1B of the above-described
processing flow. Briefly, structure 200 includes substrate 101,
along with gate structure 110 overlying channel region 102 within
substrate 101. In one example, gate structure 110 may include a
sacrificial gate material 112 and sidewall spacers 114, as
described above. As noted, substrate 101 may be or include a
semiconductor material, such as described above in connection with
FIGS. 1A-1C. Substrate 101 is recessed adjacent to channel region
102 to form one or more cavities 130 therein, including, for
instance, a source cavity and a drain cavity, separated by channel
region 102, as illustrated. Isolation regions 120, such as a
shallow trench isolation, at least partially surrounds the
transistor, which as noted, may be (for instance) a planar
field-effect transistor or a fin-type, field-effect transistor. At
the processing stage of FIG. 2A, first horizontal cavity surfaces
132 and second vertical cavity surfaces 133 of cavities 130 are
exposed. Note that cavities 130 may have been patterned and etched
as described above in connection with FIGS. 1A-1C.
[0032] FIG. 2B depicts the structure of FIG. 2A, after implanting
one or more dopants through horizontal cavity surfaces 132 (FIG.
2A) of source and drain cavities 130 to define implanted source and
drain regions 136 respectively within substrate 101, in accordance
with one or more aspects of the present invention. Note that, in
one embodiment, the implanted source and drain regions 136 within
substrate 101 are designed to extend the interface of the source
and drain regions relative to channel region 102 of the structure
200, defining (in part) an extended source and drain channel
interface 138 to channel region 102 of the semiconductor structure.
By way of example, the dopant(s) may be implanted into substrate
101 via, for instance, an ion implantation process employing
controlled process parameters such as, for example, implantation
energy, implantation dose and/or implantation angle, so as to
facilitate minimizing or preventing lateral diffusion of the
dopant(s), for instance, into the adjacent channel region 102
disposed within substrate 101. Note that this minimizing of the
lateral diffusion of the dopant(s), which may also be referred to
as lateral straggle of the dopant(s) advantageously facilitates
controlling location of the interface of the implanted source and
drain regions 136 to the adjoining channel region 102. For
instance, the dopant(s) may be implanted into substrate 101 through
horizontal cavity surface 132 (FIG. 2A) of source and drain
cavities 130 at an implant angle which is normal to horizontal
cavity surface 132. Note that the implant angle being normal to
horizontal cavity surface 132 advantageously facilitates forming
the interface of implanted source and drain regions 136 to the
channel region 102 substantially coplanar with respective vertical
cavity surfaces 133 (FIG. 2A) of source and drain cavities 130, as
depicted in FIG. 2B.
[0033] In another example, the dopants(s) may also be implanted
into substrate 101 through horizontal cavity surfaces 132 (FIG. 2A)
of source and drain cavities 130 with an implantation energy which
facilitates controlling depth of the implanted source and drain
regions 136 extending into substrate 101. Note that such
controlling of implantation energy advantageously facilitates
controlling depth of the interface of implanted source and drain
regions 136 to channel region 102. In one example, the depth of the
respective implanted source and drain regions 136 extending into
substrate 101 may be within a range of about 5 to 30 nm.
[0034] By way of example, the one or more dopants implanted through
the horizontal cavity surface 132 may be a p-type dopant or an
n-type dopant. As used herein, p-type dopant refers to the addition
of an impurity to substrate 101 (including, for instance, an
intrinsic semiconductor material) to create deficiencies of valence
electrons. Examples of a p-type dopant may include boron, aluminum,
gallium or indium, any one or more of which may be added to
substrate 101, which may itself include, for instance, a silicon
material. In a specific example, substrate 101 may be implanted
through horizontal cavity surfaces 132 (FIG. 2A) of source and
drain cavities 130 with a p-type dopant such as, for instance,
boron or a compound of boron (for instance, boron trifluoride
(BF3), octadecaborane (B18H22)) by employing an implantation dose
of about 1e14 to 2e15 atom/cm2, with an implantation energy of
about 2 to 10 keV, to define implanted source and drain regions 134
respectively, within substrate 101. An n-type dopant refers to the
addition of impurities to substrate 101 (including, for instance,
an intrinsic semiconductor material) which contribute more
electrons to the intrinsic material, and may include (for instance)
phosphorus, antimony or arsenic. In a specific example, substrate
101 may be implanted through horizontal cavity surfaces 132 (FIG.
2A) of source and drain cavities 130 with an n-type dopant such as,
for instance, phosphorus or a compound of phosphorus (for instance,
heptaphosphane (P7H3)), by employing an implantation dose of about
1e14 to 2e15 atom/cm2, with an implantation energy of about 5 to 25
keV, to define implanted source and drain regions 134 respectively
within substrate 101.
[0035] Continuing with FIG. 2B, structure 200 may be subjected to
an annealing process to facilitate stabilizing the dopant(s) within
the implanted source and drain regions 136, to facilitate achieving
a desired configuration and distribution of dopants within
implanted source and drain regions 136. Note that, the crytal
lattice structure of the silicon substrate material may be altered,
for instance, during the ion implantation process, resulting in the
dopants of the implanted source and drain regions 136 being weakly
bound to the silicon substrate material. Upon performing a high
temperature annealing process, the crystal lattice structure of the
implanted source and drain regions may be adjusted to better
position the dopant into the crystal lattice structure of the
implanted source and drain regions, thereby stabilizing the dopants
within the implanted source and drain regions. The high temperature
annealing process may be performed using, for instance, a spike
annealing, laser annealing, rapid thermal annealing (RTA), flash
annealing or the like. In one example, the high temperature
annealing process may be performed using an RTA annealing process
at an elevated temperature of about 950oC to 1050oC in the presence
of inert gas such as, Argon (Ar), having a pressure of about 1 atm
pressure.
[0036] Additionally, in another embodiment, the dopant(s) may be
implanted into substrate 101 through the horizontal cavity surfaces
132 (FIG. 2A) while controlling the process parameters such as, for
instance, implantation angle and/or implantation dose employed to
facilitate altering the positioning of the interfaces of implanted
source and drain regions 136 within substrate 101 relative to the
vertical cavity surfaces 133 (FIG. 2A). In one example, the implant
angle and/or implantation dose employed during the ion implantation
process may be controlled so as to facilitate providing a
non-planar interface relative to the vertical cavity surfaces 133
of source and drain cavities. For instance, the implant angle
employed during the ion implantation process may be within a range
of about 5 to 30o, while the implantation dose (e.g., Phosphorus)
may be within a range of about 1e14 to 2e15 atom/cm2. In another
example, the dopant(s) may be implanted into substrate 101 through
horizontal cavity surfaces 132 (FIG. 2A) at an implant angle which
results in extending the interface of the implanted source and
drain regions 136 within substrate 101 at an angle relative to the
vertical cavity surfaces 133 (FIG. 2A). In a specific example, the
interface of the implanted source and drain regions 136 within
substrate 101 may extend at an angle of about 5 to 30o, relative to
the vertical cavity surfaces 133 (FIG. 2A).
[0037] FIG. 2C illustrates the structure of FIG. 2B after forming
source and drain regions 134, at least partially, within source and
drain cavities 130 (FIG. 1B), and more particularly, over the
respective implanted source and drain regions 136 of substrate 101.
In one embodiment, source and drain regions 134 may be formed by,
for instance, epitaxially growing a source and drain material from,
in part, the exposed implanted source and drain regions 136 of
substrate 101 within source and drain cavities 130 (FIG. 1B).
Epitaxial growing refers to an orderly growth of a crystalline
material, where the grown material arranges itself in the same
crystal orientation as the underlying structure. In one example,
source and drain material may be epitaxially grown using selective
epitaxial growth via various methods such as, for example, CVD,
low-pressure CVD (LPCVD), or other applicable methods. By way of
example, in the case of a p-type, field-effect transistor, the
epitaxially grown source and drain regions 134 may be doped silicon
germanium-based epitaxy, and in the case of an n-type, field-effect
transistor, the source and drain regions 134 may be silicon-based
epitaxy.
[0038] Note that, in this embodiment, sidewall interface 140 of the
epitaxially grown source and drain regions 134 and interface 138 of
the implanted source and drain regions 136 together, provide
structure 200 with an extended source-to-channel interface and an
extended drain-to-channel interface, respectively. These extended
source-to-channel and drain-to-channel interfaces are extended
because the interface to the channel region 102 extends into
substrate 101. In one example, the depth of the interface 138 of
the implanted source and drain regions 136 relative to the depth of
the sidewall interface 140 of the epitaxially grown source and
drain regions 134 may be within a range of 5 to 100%. Note also
that, as discussed above, the implanted source and drain regions
136 formed by, for instance, controlling of the process parameters
via, for instance, ion implantation, allows the position of the
extended source-to-channel interface and the extended
drain-to-channel interface relative to the channel region to be
controlled. For instance, in one embodiment, interface 138 of the
implanted source and drain regions 136 to channel region 102 may be
at an angle relative to the respective sidewall interfaces 140 of
the epitaxially grown source and drain regions 134, as illustrated
in FIG. 3A. Further, depending on the implant angle employed during
the forming of the implanted source and drain regions 136,
interface 138 of the implanted source and drain regions 136 to the
channel may either be parallel (FIG. 3B) or non-planar (FIG. 3C)
with sidewall interface 140 of the epitaxially grown source and
drain regions 134 as illustrated.
[0039] Advantageously, one skilled in the art will note that the
fabrication processing of FIGS. 2A-2C facilitates in extending the
source-to-channel interface and the drain-to-channel interface into
the semiconductor material of the semiconductor structure, thereby
facilitating operation of the resultant device. For instance, the
extended source-to-channel interface and the extended
drain-to-channel interface would advantageously facilitate
increasing junction on-current, while minimizing junction leakage
current of the resultant semiconductor structure.
[0040] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a," "an," and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprise" (and any form of comprise, such as
"comprises" and "comprising"), "have" (and any form of have, such
as "has" and "having"), "include" (and any form of include, such as
"includes" and "including"), and "contain" (and any form of
contain, such as "contains" and "containing") are open-ended
linking verbs. As a result, a method or device that "comprises,"
"has," "includes," or "contains" one or more steps or elements
possesses those one or more steps or elements, but is not limited
to possessing only those one or more steps or elements. Likewise, a
step of a method or an element of a device that "comprises," "has,"
"includes," or "contains" one or more features possesses those one
or more features, but is not limited to possessing only those one
or more features. Furthermore, a device or structure that is
configured in a certain way is configured in at least that way, but
may also be configured in ways that are not listed.
[0041] The corresponding structures, materials, acts, and
equivalents of all means or step plus function elements in the
claims below, if any, are intended to include any structure,
material, or act for performing the function in combination with
other claimed elements as specifically claimed. The description of
the present invention has been presented for purposes of
illustration and description, but is not intended to be exhaustive
or limited to the invention in the form disclosed. Many
modifications and variations will be apparent to those of ordinary
skill in the art without departing from the scope and spirit of the
invention. The embodiment was chosen and described in order to best
explain the principles of one or more aspects of the invention and
the practical application, and to enable others of ordinary skill
in the art to understand one or more aspects of the invention for
various embodiments with various modifications as are suited to the
particular use contemplated.
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